My 99 1/2 ton 5.2 just started making w
"Wrenching-Clicking-Noises"...Is full on fluid, run truck in 2-Hi, no problems other than it gets HOT in all conditions.
But in 4-Hi, and turning corners/ figure 8s' etc, the case will make these noises, and get very hot..Front & rear diff. oil is full as well..

Any ideas?

 

Rear output shaft snap ring has abandoned the shaft maybe. Drop the rear driveshaft, pull the tailhousing, see if it is still there.

Is the engine running hot? Or the t-case?

 

Yes! transfer case itself gets very hot..Even in 2-Hi around town..
But NO noises unless in 4-Hi...Leaking ATF as well, but cann ot tell from where.
I did notice that the case itself was cracked near bolt threads where it mates to transmission..Tried the old "JB Weld" to gum up the cracks..
I fear it may be cracked up to as well.
I'm now a disabled Vet, and can't get too physically into seeing where the leak is, but I can't make heads or tails if this may be a front differential, "Open Knuckle" U-Joints, or a combination of all !

transfer case does get very hot though in 2-Hi..

Bummin!

 

Engine runs normal op, temp.
Transmission isn't hot..
Seems isolated to Drivetrain..

 

I'd say the transfer case is hosed if it's cracked. And the seals are shot, that's why it leaks.

 

I agree here..Since it appears that the trans. is costantly losing fluid through the
T-Case, due to the cracks, I'll probably have to replace the Transfer case..
Thank God that Dodge was smart enough to use ATF+4 (7176) fluid in both!

Now to find a dependable company to buy a case from..Jasper has always given good results with their engines & 100,000 mi. warranty..
I'll let ya know what happens!

Thanks for the input!

 

Wait a second,

You said while you're in 4hi, you're doing figure eights and turning corners?

That's not advisable in a 4x4 truck. With an "all" wheel drive car, it's not a problem. Turning corners while in 4x4 will stress the drivetrain immensely, until the weakest component breaks.

Good luck finding a replacement case, and let us know what company you go with. I didn't know Jasper sells rebuild transfer cases.

-JT

 

Wow! In all the years I turned wrenches, I did not know this!
As far as cranking the wheel to the maximum and doing "Fig-8s'!
If I just drive normally in 4-Hi it's fine..I guess I was "Overtesting"!

I suppose I will leave well enough alone for now..As it does fine if I don't attempt to destroy it! Too many I'E'D's' over there!

Now, should a transfer case get hot, under normal 2WD driving?
(Obviously I never did take the Powertrains/Manual Trans. ASE!)

Thanks!

 

Mine gets warm on top of the floor too.
Is that what you are talking about? Mine runs fine. Fluid is fine and engages fine on mine. I really wonder if it is carry over exhaust heat...

 

Good one there!
I recently had a new single RH side pipe & Glasspack put on mine...
I'd be willing to bet so! Man I put that thing through a test. I was trying to diagnose maybe a worn U-Joint in the left "Open Knuckle" axle, when I noticed this stressing Transfer Case. When I sould have just grabbed the 4' prybar & checked for play in the joint itself..
About to snow here in KC, so I won't see how close that pipe is 'till tomorrow morning. I do know that the pipe IS about 3-5 " away from the case in one spot near RH seat..

It doesn't get so hot that you can't keep your hand on it, but close..
I had a 2001 that had a RH "Knuckle Joint" that failed. Sounded like a ball bearing rattling around inside a wheel Center Cap..