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Well front axle is fixed. Pinion race and bearing was the culprit. Noise transmitted to the t-case through the driveshaft.

Yup it sux.

Swapped in a known good working transfer case...Same noise. Narrowed it down to the front axle I had rebuilt,lots of metal in the lube and on the magnet I put in there. Rear will have to come apart...

Tried another complete shaft. And still same noise. Checking transfer case next.

And it looks like your missing that rubber sleeve that semi protects that ball.

Yup,thought it might be toast when I took it apart but it was in pretty good shape,not dry. Took all those needle bearings out,cleaned everything up and greased it all up.Took the unit apart again...

Upon close examination I am finding an "R" stamped on th shaft and an "R" on the center piece of the double cardan joint and they are facing opposite directions. Can it be that simple? Really don't...

Test drive without front shaft and in 4wd high and low...no noise. My shaft rebuild must have something to do with this noise. Any good pics of one? Is there a way to tell the proper way for all of...

Front different is rebuilt,75/90 synthetic in it. Rear is fine. Mudderoy did you mean remove the shaft and RUN it in 4wd?

I'm pulling the drive shaft next.Giving it a good look over. And test driving without the shaft.Will report back in a short while.

Changed lube in t-case to mercon V.That's the only mercon I could find at auto zone,no difference. On the test drive,dry road,only engaged 4wd on straight section of road (no turning on dry road in...

Front different fluid new,75/90 lucas full synthetic. Rear,8.25 came from low mileage junk yard donor.It was clean so I left it alone.Plan on changing that at a later date.

And yes I'll change the fluid first and try that..much easier. And you said straight mercon?

So take the front shaft off and put it in 4wd?

Straight mercon you're saying? I checked t case before I changed it,it was a little low and dark.

Could that be the issue?

Not sure. Wish I wouldn't have changed it. That would have eliminated one option. On the rebuilding of the double cardan shaft..I didon't keep all the parts in the order they were in. Tore it...

I stalled drive shaft last night changed T.Case fluid today. Also drained transmission today and filled with dex merc,no new filter,just a drain and refill.

Read somewhere ATF+4,alot of people use whatever with no issues. Still I don't think that is what is causing my noise.

Yea just changed it. Atf+4.

It's like a mid to high pitched sound.And only in 4wd.Sounds like from transfer case area.hard to locate exactly from inside and driving.

Ok, so I had my front axle ring and pinion bearings replaced. Rebuilt the front double cardan drive shaft myself.Put it back together and now I get a strange sound from underneath only when in 4wd...