Transfer case noise?

[Tobyspaw]

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 low and high.Examined front shaft and notice one of the u joint retainers is not seated properly,so I fix that and reinstall shaft 180 degrees from the way it was just in case that was the reason. Changed transfer case fluid atf+4. Still making same sound. Help!

[4.3LXJ]

Describe the strange sound

[Tobyspaw]

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.

[4.3LXJ]

Check the oil in the tcase lately?

[Tobyspaw]

Yea just changed it. Atf+4.

[Mudderoy]

Yea just changed it. Atf+4.

I use the same fluid that I use in the AW4, Dex/merc

[Tobyspaw]

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

[4.3LXJ]

Did you change the fluid at the same time you repaired the driveshaft?

[Tobyspaw]

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.

[4.3LXJ]

What I am trying to get at is the noise showed up with the fluid change or the drive shaft fix

[Tobyspaw]

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 apart,sandblasted it,painted it and,put it back together.

[Tobyspaw]

Could that be the issue?

[4.3LXJ]

Since you have a whine, I am inclined to say it is the tcase. But to be sure you might change that oil again and put some mercon in it. Generally driveshafts vibrate not whine. But, it is hard to tell right now with both variables

[Tobyspaw]

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

[Mudderoy]

I think it you said it was the front drive shaft? Kind of a pain, but remove it and see if the whine goes away.

Hows the fluid in the diffs?

[4.3LXJ]

Yes, change out the oil completely

[Tobyspaw]

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

[Tobyspaw]

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

[Tobyspaw]

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.

[Tobyspaw]

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 4wd).Noise is not immediate, but after movING a little ways and applying throttle and not so much of a whine.More like a whirr that gets a louder pitch the faster I go.

[Tobyspaw]

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.

[Tobyspaw]

I think it you said it was the front drive shaft? Kind of a pain, but remove it and see if the whine goes away.

Hows the fluid in the diffs?

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

[Tobyspaw]

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 it to go together?

[Tobyspaw]

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 want to tear this apart again,but....

[4.3LXJ]

Could be. Let me see if I can find some images. Been a long time since I tore one apart.

[4.3LXJ]

fortunately I had my shafts out to take a look at. With the piece on the tube end being welded in, it is not possible to put it together backwards. However, did you grease the ball and socket properly before assembly? That might cause the noise you are describing

[Tobyspaw]

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 tonight and lined up the 2 R's. Also found some center punch dots,3 here,2 there,and lined them up as well. Will reinstall in the morning and test. My driveshaft does not have a flange like the one in your pic.

[Tobyspaw]

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

[4.3LXJ]

I shouldn't be. I bought that one new from Tom Woods. It is newer and larger than yours

[Tobyspaw]

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

[Tobyspaw]

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 again.Probably new bearings and races again.

[4.3LXJ]

Man, you and 07Negative are both having gear problems from vendors.

[Tobyspaw]

Yup it sux.

[Tobyspaw]

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