On my 96 2500 I was driving home a few days ago and heard a grinding noise similar to the noise when a starter is engaged on an already running motor. It happened sporadically but never more than a second. I somehow found out that it only happens in 2 wheel drive, so I thought it might be the collar on the front axle that links the inner and outer shaft.

I took it to a shop since I didn't have time to deal with it and told them my idea and after a week they diagnosed that I needed a new transmission!

I brought it home and put in a new vacuum actuator since a buddy told me the same thing happened to him and that was the problem. Well it didn't work, noise still happens, the shift fork was slightly loose on the actuator shaft but now I am uncertain if I am on the right track or need to look at something else.

Any help would be appreciated. Thanks

 

Welcome to DF!

Auto or manual trans?

 

Can you tell where the noise is coming from? What did they was wrong with the trans?

 

Maybe the clip on the transfer case output shaft?

 

Thanks all ,It has a auto transmission, I've had it rebuilt but lost overdrive a while back so it could definitely use a rebuild but I do very little highway driving so not having OD isn't worth the $2000-2500. They just said it needed a rebuild, no specific reason.

I cannot really tell where it comes from, it seems to be from the front right corner but again I have become fixated on axle.... I drive the truck everyday in 4-wheel drive and never hear anything until I disengage.

I was wondering whether something was bad with the transfer case. It has a leaky rear seal which is on my to do list. All the yokes on the front and rear drive lines seem solid with no wiggle. Rear axle and driveshaft were recently rebuilt by a very good shop so I don't think that should be an issue..

Thanks for helping!!!!

 

https://dodgeforum.com/forum/2nd-gen...driveline.html

Then do a search for transfer case saver.

It's a real quick check to see if your snap ring is out of its groove. Just need some RTV.

 

Do you get good vacuum to the outboard port on the cad actuator in 2 wheel drive? Is the cad disengaging completely?

 

Sorry it took so long to get back with you. I wasn't able to work on the truck over the holidays. But I wanted to thank you all for the ideas. It turned out to be the clip on the rear output shaft. I checked vacuum on the actuator and it seemed good, so figuring I needed a new rear output seal why not tear into the transfer case. Once apart it was obvious the clip was gone. then chunks started falling out of the rear output shaft housing? 30 minutes and $21.00 ($19 for the seal and $2 for the clip) later it was back together and running like a champ!!! I didn't do a transfer case saver because I couldn't get one quickly and the gear shop I went to said the clip I put in is the revised clip from OEM and would last.


I wish I would have asked the question here first before spending $80 at a shop and $120 on a new vacuum motor!!!!!


Cant thank you all enough!!!!

 

Think I would still be tempted to order up a t-case saver, and install it.

But, glad ya got it going in any event.