My opinion is the xfer case, These come supplied with the same xfer case as my jeep did. Jeep was making the saqme noise you are talking about wound up being the chain was loose and jumping teeth on the gears. Rebuilt my transfer case and everything worked fine there after. But then again your problem could be something different altogether

 

Thanx eveyone for the info, i will pull it all apart this spring from the t case front shaft to the axle locker and i will let you all know where the problem lies!!!
Thanx

 

Anyone know how hard it is to re-build a transfer case? My truck (since I put my trans back in) won't let me shift into neutral or 4-lo. All I have is 2-hi and 4-hi. I think it may just be a linkage issue, but just thought I would check.

 

transfer cases are simple, just keep track of where the snaprings and springs go as you take it apart.

 

Yeah, I just rebuilt my trans and that was a PITA, but it didn't go too bad. I figure if I could tackle that then I could re-build the transfer case no prob.

 

Well, my guess is if it worked good before you took it out (guessing you did when you removed the tranny) and now it doesn't shift correctly, it is most likely within the linkage somewhere. I would try adjusting that before removing the tcase.

 

Yeah, I def. plan on it. I have to crawl under my truck again this weekend to tinker with some stuff anyways.