copied from another thread ..

the transfer case really doesn't weigh much... about 75 lbs. So if you can bench 75 lbs, you can lay on your back and get it down. All you have to do is unhook the wires and vacuum lines, shift linkage, unbolt both driveshafts and unbolt the nuts on the 6 studs coming out of the case going into the back of the transmission. Very easy to do!

 

If the noise went away when you removed your t-case, I would check your front end too. CV's and differentials in the front don't like being run all the time and it looks like that is what happened.

 

The noise isn't gone, it just lessened because it can't ring through the whole front end anymore. As for the front end being damaged i should be alright. It was parked less than 100 miles after the noise started.

 

.....

 

if noise is gone... issue is upfront not tcase.... sorry just seen this post :O since tcase is still in operation the same as with the front shaft on... if chain was slipping bad u would hear it...

anway for the cost and time pop front diff cover off and check it out... also remove the central disconnect vacuum control and check out inside there and its proper operation...

 

I shouldn't have said gone.. it has lessened. The noise is from the t case though.
I'll pull the diff cover anyway though and check it out.. cheap and easy.
As for the disconnect i thought those were removed after 93?

 

I thought it was there till 95 .. last of obd1.... could be wrong.. seen a 94 that had the Axle disconnect... guess only way is to check...

this is why I asked if u can raise rear now that front shaft is off front wont spin when rear is lifted as it would while its on the road moving :O

 

Good idea, i'll give that a try tomorrow.

 

I did mine this past summer. You have a NP231 D or possibly a NP231 HD (look at the tag). You'll also want to record the assembly number ( something like 5209 XXXX). Dealers need this info to hook you up with the right parts.
I bought a junkyard case for 350, and paid 150 or so for a hard to find planetary with all six holes drilled out (this is optional- you don't need this unless you wish to go with a six gear planetary).
I also popped for a wide chain which necessitated wide drive and driven sprocket pair, say 600 bucks for all the parts. I bead blasted the case and installed the parts. I now have the ultimate NP 231 transfer case.
You don't have to spend as much as I did, you can get by with what you have and a complete rebuild kit, say 225 dollars. Do a search for NP 231 in Google. You will find all sorts of info and shops offering help. Two of the best are JBConversions and Novak Conversions. I went with Novak. Dave there bent over backwards to get me everything I wanted to build my "ultimate NP231". I see you have a '95, this means you almost certainly have a planetary with the later narrow teeth on the gears (including the non-removable ring gear in the front case half. This is only important in the unlikely event that you need to replace anything to do with the planetary assembly. You must then use parts with matching teeth.
As stated a few posts above, the job isn't that difficult. Just take the time to carefully install a rebuild kit (including a new chain!) and you'll be good to go for years.

 

Thanks for the info! I can't get a used case out of a truck at the local junk yard for $60. I just need to wait for one to show up.

There's a 97 out there but it was pretty greasy and i wasn't sure if it was still good or even if it would fit. I'll check out the rebuild kits and go from there.