I have a 99 2500. Never had a problem with 4x4. Always change the fluid every year. Lately when in 4x4 the trensfer case makes a bit of a rattling sound but eventually goes away. I think its coming form the case. Just changed the fluid again yesterday. No metal in it. 4x4 still works. Any ideas? Thanks

 

Look into one of these http://www.drivetrain.com/parts_cata...ase_saver.html and check your front driveshaft.

 

Driveshaft seems okay. I did both u joints a year or so ago. It makes the noise in 4L as well.

 

sure it goes away? may be a sloppy chain, if so keep it out of 4wd. chain doesnt move in 2wd

http://www.youtube.com/watch?v=svZ8gwCpo9k

 

If it is a broken snap ring your transfer case is in grave danger. Check that out right away, and replace it with the transfer case saver if it's broken. Or even if it's not.

Another possible cause is a broken mount, or a sloppy transfer case chain. If the chain is slapping the case it's just a matter of time before very bad things happen.

 

What would cause the chain to go slack all of a sudden its been working fine. Is there a tensioner or adjuster on it?

 

no tensioner, it should be a gradual process, verify the noise first.

 

Well what i thought was my transfer case turned out to be the front ujoint on the output shaft to front diff. Replaced it 2 years ago. One cup ceased solid.27 bucks. Good as new.

 

Wrong again! The noise is back. Sounds like the u joint at the transfer case. One of the two. Is there a bearing on the output shaft as well. It was squeakin a bit too when i turned it by hand. Is that a big job to replace the bearing and seal? Also to get the output shaft off do you undo the 4 bolts holding the yoke? Thanks

 

Fix the ujoints first. See if that doesn't take care of it.