The other day I was driving on our ranch and needed to use the 4x4. So I switch into four and I hear a very loud grinding metal to metal sound. I'm guessing the transfer case is shot. My truck has 138000 miles on it, so the warranty is out of the question. I asked one of my buddies and he said it might be a planetary or the diff, I was just asking for a second opinion about the noise I'm hearing.

 

Did it just happen once or does it happen every time? My 4x4 has grinded a few times; normally when I switch it and use it too fast.

 

the transfer case is one of those things you have to crack open to see whats wrong, could be a number of things such as the planetary as you friend says
also check the clip on the rear output shaft of the transfercase. you will have to take the tail housing off first. the clip will break and cause the shaft to slide in to the T-case and grind on chain.
I know on some t-cases when the chain gets loose it will drag on the bottom of the case but could also be something as simple as a fluid issue

you can also try this
- put it in 4wd and turn the wheel tight then give it gas, half throttle or better, it the truck shudders, and bucks, the the chain is stretched and needs replacement. (it is jumping the gears). if thats not the case i would lean more towards your friends diagnosis and say planetarys are coming apart

 

It happens anytime I have tried to put it in four since then. I engage the switch, the clunking starts so I disengage the switch and it takes it awhile to actually disengage. I'll check out that tail clip tomorrow. I'm really hoping that dont have to replace an entire transfer case.

 

I rebuilt my np231 on my old dakota without any prior t-case rebuilding knowledge. The NV233 is essentially a newer version. I found a rebuild guide online and followed it step by step. The complete rebuild kit including chain was $165. It is actually a pretty simple process as long as you take your time. My total time was about 8hr and that was because I went slow and took ALLOT of pictures as I tore down to reference as I put back together. Another option is to check local boneyards or www.car-parts.com You might be able to find a t-case with low mile cheap and just swap it in.

 

Well I climbed up under the truck today to check things out and I figured out the sound isn't coming from the transfer case, it's in fact coming from the front diff. I also found a nice little hole on the back part of the front drive shaft where you hook into the transfer case. =/ Any suggestions?

 

dont know about that, you could try to take a pic of it.......

 

Here's a picture of the front driveshaft.

 

I do not really recall what the front actually looks like stock, but something is missing in this picture.

 

Here's a pic of mine from the same angle. Something dont look right with yours.....like something definitely is broke. Look at where the paint is flakes off, looks like a big dent from the inside....