Got the driveshaft back on and 4x4 still bangs and clacks. Tomorrow im going to get a video for you guys.. But here's the real kicker.. As I mentioned earlier, my transfer case shifted stiffer after I put it back together. Had to put it into neutral and shut the truck off to go into 4L. To my knowledge and with my dad having the same truck, this appears to be pretty much the normal. When I test drove it in 4x4 for the first time tonight it didn't clunk for probably the first 6 times back and forth in my driveway and when it did it was a very silent click.. The more I tried it the worse it got and now my 4x4 shifter has slop in it. Not slop per-say but I can shift through all the 4x4 gears without a single grind again and no longer need to shut the truck off for 4L.

 

Just got back from my buddies place. We decided to pull apart the tcase again. What we found is that one of the shift fork pads was messed up so I replaced it and put it back together. Drove about 2 miles in 4H and another mile in 4L. Worked like a dream. Not a single clunk. I was sooooo thrilled. I was about to come on here and tell you guys we fixed the issue. Left my buddies place and tried it again when I got home. Clunk clunk clunk.......

 

Here's a video from this afternoon. It's not banging anymore so I guess that's a start. Just clacking.

 

Check the double cardan joint on the front driveshaft right at the t-case. That sounds REAL familiar to me.

 

But the thing is last night I didn't touch the Cardin joint, only replaced clips in transfer case, and the 4x4 worked awesome until I tried it again after. Now this noise is a lot quieter but a lot more frequent. Cardin joint seemed fine when I had driveshaft off.

 

A dry joint would do just that. Do they have zerk fittings? Could try hitting them with some grease..... see if that does anything.

 

I have a spare driveshaft sitting in the garage so tomorrow I think I'll swap the shafts just to check. But why would the 4x4 work so awesome yesterday after reinstalling new clips?

 

It's just F*****G with you.

 

HeyYou, I've doubled checked the Cardin joint and I've even swapped driveshafts to make sure and the noise still exists. Is there any way this noise can be from something out of adjustment? I ask this because the noise went away that one time. I'm unsure if the shifter linkage can make this noise but it appears to be adjusted. I also noticed when I was inside the tcase that there is an adjustment screw on the bottom of the tcase and it goes to one of the forks. Any chance it could be this? I'm getting low on ideas

 

Not sure. haven't been inside mine yet, but, from the sounds of yours, I am going to be in the not too distant future.

Is your chain stretched out?? That's about the only thing I can think of that would make those kinds of noises.