The chain is surprisingly tight. I'm assuming it was replaced before I bought the truck. If I can find a tcase for cheap ill buy it and swap I'm just trying to avoid that because I'm unsure if it even is the tcase.

 

Mine only makes those noises in 4wd, while turning. Tighter the turn, louder the noises. I don't *think* its the front axle itself, as it doesn't sound like it is coming from there..... and I am not about to lay under the truck while someone else moves it around.... Oh hell no. My front shaft doesn't appear to be in bad shape, but, I suppose, if the slip joint was worn, it might make those kind of noises, but, it would have to be REALLY worn.....

 

If your noise only happens while turning then I would narrow out the tcase for sure. Mine does it if im going straight, turning, etc. I can't see it being your driveshaft either. Shouldnt matter if its turning or not. Have you checked your axle ujoints?

 

Axle U-joints *look* good, they even have zerk fittings. (so I greased them. made no difference.) Turning puts more pressure on the front driveline, so, more prone to make funky noises if something isn't quite right.

 

Have you checked your pinion angle?

 

No I haven't but it seems okay. I know the noise travels but it sounds like transfer area end.

 

Take a couple pics from the fender well angle area looking at the yoke/ds

 

Okay, will do tomorrow.

 

If you had to replace your transfercase shift fork pads, there's a pretty damn good chance the pads on your CAD actuator are toast. Pull that CAD off and inspect - worn out pads on a CAD will cause a noise like that. If they have any grooves, replace them. Also check that fork to make sure it is straight up and not cracked or even in the odd chance bent. Make sure it is on that shaft tight - there should be little free play when you wiggle it.

Inside that double cardan ujoint on the front driveshaft is a centering joint - if it is bad your drivershaft will bind up, and could cause the clunking noise. If it's bad, probably gonna need a new yoke cuz those centering joints LOVE to wear their races out of round. A yoke is about $65 in the US FYI

 

i listened to the video and the metal clacking gives me cold chills.

if you put the truck up on jack stands, can you operate it and reproduce those sounds? If so, you can follow your ear.

If not, get a buddy to get down on the floorboard and see if its coming from the tcase or the front axle cad. maybe? remove the tcase shifter boot to stick his eyeball or ear down in the hole.

important --- earlier you mentioned reproducing the sound by sticking the front end in a snowbank, and observing that the front drive shaft would stop turning while it clacked. is it still doing that? if so, i'd guess the chain's drive sprockets might be worn out. so the chain might be new and tight, but could the sprocket be slipping in the chain. or could it be the wrong chain.