Had to replace the transfer case shift motor the other day on my 05 Dakota QC V8 4x4 and after I fixed it and tested the 4wd I noticed a grinding noise coming from the front anytime there was significant power sent to the front. It sounds like it is coming from the front differential not the t-case but I could be wrong. Any ideas? A few threads on the ram section suggested the CAD coupler, but I don't know what that is.

 

same thing happened too mine.. the front CV joint in the front drive shaft was broken.

 

I put up a video on youtube of the noise . The sound is really clear around 45 seconds. My dad seems to think that it is the CV joint too, but I don't want to spend six hours and $150 unless I'm sure.

 

That sounds worse than a CV joint, which will just make a clicking sound. Did it do this before the shift motor replacement? Why did you have to replace the shift motor?

 

maybe the chain is starting too show wear? whats the mileage on it?

 

Sorry for such a late post I must have forgotten to put a post-fix update. It was the CV joint on the forward output shaft. The ball bearings were rusted to hell and I must have knocked them out of place when I removed the shaft to get to the shift motor.

A picture of it.
http://i1344.photobucket.com/albums/...psdfrelsyt.jpg

How to tell that it is actually the CV joint.