So the other day i went to pull my boat out of the lake. Had to use 4x4 due to the very low water level. When i went to pull ahead, it just made some noises like it was the chain skipping. So i tried it in 4low, it was worse. Anyone have any ideas on what it is? It never happened before until now, i havent used four wheel drive since about april. Just checked the fluid level, it was a bit low, but it still does it. This is my DD, and i don't have alot of money to drop it off at a shop to have it fixed. Im very mechanical inclined, have built a few engines and trucks on my own. If anyone can help me or point me in the right direction it would be greatly appreciated.

 

welcome to df...

there is a post tacked to the top of the forum that has a link to a 2001 service manual. I would download it and see what it has to offer. you may have to dig into the transfer case to find the problem. does it do it in 2x4 at all?

 

No, it doesnt do it in 2x4, but it is making a funny noise, kinda like a clicking noise when moving, whether the clutch is pushed in or not, in gear or in neutral. Im just hoping its the chain. Gonna pick up a chain, new seals for the input and output shafts, and if it needs new bearings, i can get them. Probally going to do it next weekend, if it lasts that long. I drive 20 miles a day to and from work, so i does bother me all the time. I cannot find a used transfer case in New England, and a rebuilt one is around 1K, which is 1K that i dont have.

 

check your u-joints... another thing to do is put it on 4 jack stands, put the TC in neutral and rotate the drive shafts. while they are spinning you could put a mechanics stethescope on the t-case to see if the clicking is coming from within.

 

Well the clicking noise sounds like its coming right behind my shifter, like under my console. It just started doing it after i pulled the boat out. When i had it in 4x4, hi range, it was like it was bucking, or jumping, while making that noise. I crawled under it after and turned the front driveshaft and you could hear like that clicking noise, but only as far as the driveshaft would turn (like not even a 1/4 turn due to the tires sitting on the ground) and i did the same with the rear driveshaft and it didnt do anything. I just hope whatever it is is fixable, because winter is right around the corner, and this truck with the LSD in the rear and 33's is just about useless in the snow. Even with my MXZ 700 in back it still doesnt hook up, and that sled is about 600 pounds.

 

could be the front DS output bearing... hard to say w/o being there to hear it. did yo download the maunal? I'd also go to dodge and see ifyou could get an exploded view of the front part of the transfer case, that may help as well.

 

I had a transfer case problem in about april. the case cracked and then blew a hole in the casing and eventaully the chain broke ( in the mehcanic parking lot). the sound it was making was like a chain slap/clicking, make sure you dont have any cracks in the casing itself thats the only reasong why i had to replace the entire TC. Also where in New England are you, im in western MA and i found my transfer case in northern ct i paid 500-525 for it dotn exactly remeber. Also make sure you get the right transfer case the cases are all the same except for the output shaft i learned that hard way when the bione yard tld me theay will work from any 4wd dak

 

nice. Yea, its making a clicking sound when just driving around. Did you or the mechanic take apart the the TC and find what was the problem? Mine is not cracked, i looked it over pretty good the other day, trying to pinpoint my dripping leak. Its just dripping at the bottom, where the 2 cases come together. I keep a good eye on the level, and about once a week i usually put 4-5 ounces back in it. Im hoping its just the chain, i havent tore it apart yet, due to no time or money, but still driving it, praying every minute im in it it won't come apart on me.
I kinda figured that all transfer cases wont fit. All the ones i find are out of automatics, and the guy at the salvage yard told me that the manual and automatics have different input shafts, the spline count is different. I was wondering if i could take the input shaft out of mine and put it in the automatic, but i'd hate to spend $500 on one and find out that they aren't interchangable.

EDIT: im in central Maine.

 

Well today i ordered a new chain ($87.50), seal kit (28.60) and input and output bearings (62.86) for a grand total of 188.58. I had a hell of a time getting the part number for the chain, as there are two different widths??? So i called the Mopar garage and talked to a few of their techs and finally got an answer. The V6 model transfer has the 1" wide chain, and the V8 has the 1.25"(1-1/4") width chain. The guy at the tranny shop couldnt tell me whether it was the 1" or 1.25", as he had no info on them (and a licensed New Process dealer as well....) oh well, well this friday and saturday im tearing into it and going to see what is exactly the cause. I will post pics if i find any internal damage, im thinking about taking the front driveshaft out because i have to drive it 90 miles to my dad's house (too cold out now to work on it outside) and gonna baby it the whole way. Im just praying its just the chain, but we will see this weekend.

 

Well here is an update on the truck...come to find out, the chain was the 1-1/4", and it had to be special ordered, and wouldn't be in untill today, so for a week im without wheels.[:@] Also, the chain came off the front output sprocket, rode on the shaft, and ate away at my shift fork, destroyed the output shaft, pickup tube and screen, and the oil pump. I bought all new parts, which was pricey, but in the end its worth it. Just wanted to let you guys know, that there are 2 different widths of chains in these transfers, and i guess the dealer don't know what they are talking about, so its a hit-or-miss type of deal. Hopefully truck will be back together friday night, so i can go hunting in the morning.