So i have this problem whit my 2nd gen sport from 2001.
it started a few monts age when driving in 2 wheel drive sometimes the transfer case grinded a litlle noting to bad and just a couple of seconds so didnt think anything of it.
But a few days ago i was hauling a other 2nd gen home on the highway in 2wheel drive around 55mph and the noise come back a was shaking the whole truck so got home dropped the trailer went on a test drive and noise still was there and shaking so stopt put it in 4h and the noise and shaking was gone drove a while noting happend put it back in low en about a mile later it was back.

​​​​​​So does anyone know this problem and a fix mabey?

 

I’m wondering if the output shaft snap ring has failed, allowing the shaft (and sprocket) to move out of alignment?

Installing a Transfer Case Saver (before it goes bang) would be the fix.

 

I think i wil open it up tonight but dont have a transfer server kit but wil a new snap ring do the job?

 

Snap ring is just fine

Snap ring is just fine any other ideas mabey? Cant figure this one out

 

See if the transfer case is actually in 2wd. With the truck off can you move the lever back towards the seat and feel it go into 4wd