What’s wrong with this transfer case?

[Weasellee]

Ok

Video attached for audio purposes only. Listening for the steady thump thump. Rhythmic and consistent with speed changes.
Ben’s deployment build. When he got back to VA with his Rubicon it started making a noise. After much chasing ($$) and finally driving with microphones attached to the driveline we are pretty sure the “noise” is coming from the rear output of the transfer case.
241J Rubicon
Fluid is good
With rear driveshaft removed and driving in front wheel drive no noise.
It’s not the rear axle. Had it apart already.
It’s not the new Woods driveshaft, had it checked at local driveline shop.
Before I buy a replacement is this one fixable?
Is it ok to drive? Something’s gonna let loose eventually

What do you think about him driving it back to NY in front wheel drive so I can pull and rebuild?

Shoot



TYIA


B

https://share.icloud.com/photos/05d9dxb1CKNHqWo0bQTpidKQA

Hope this works. I’ve never uploaded to YouTube but I will figure it out.

 

[Weasellee]

I gotta work early tomorrow so I’m gonna let this soak through the night and see what happens in the morning. Thanks

 

[Weasellee]

@macleanflood maybe you’ve heard this one before? Who else ?

 

[TJ Jim]

So many places it could come from. I’d start by looking for something rubbing. Transmission touching the tunnel as a first thought.

 

[Weasellee]

So many places it could come from. I’d start by looking for something rubbing. Transmission touching the tunnel as a first thought.

But noise goes away completely when rear driveshaft is removed.

 

[Weasellee]

Maybe @hosejockey61 has ran in to this before? TYIA

 

[macleanflood]

@macleanflood maybe you’ve heard this one before? Who else ?

When I took apart my 241J four times I failed to seat my oil pump and it wouldn't shift correctly. That was while installing a SYE.

It's ridiculously easy to pull the transfer case. Front and rear driveshafts. Linkage. 6 bolts.

If you think it's the problem pull it apart and find out.

If it's a Rubicon case good luck finding a replacement.

-Mac

 

[mrblaine]

But noise goes away completely when rear driveshaft is removed.

My guess is the pinion nut worked loose, tone ring has shifted and is now eating up the tail shaft housing.

 

[Weasellee]

My guess is the pinion nut worked loose, tone ring has shifted and is now eating up the tail shaft housing.

Is this going to be repairable? Or is the housing going to be shot?

 

[Weasellee]

When I took apart my 241J four times I failed to seat my oil pump and it wouldn't shift correctly. That was while installing a SYE.

It's ridiculously easy to pull the transfer case. Front and rear driveshafts. Linkage. 6 bolts.

If you think it's the problem pull it apart and find out.

If it's a Rubicon case good luck finding a replacement.

View attachment 602918

-Mac

Easily said. I’m in NY he’s stationed in Norfolk Va. I have tools he has some. I’d rather not tow it. If we think it’s rebuildable then we can pay someone there or tow it home or drive it in front wheel drive or

 

[mrblaine]

Is this going to be repairable? Or is the housing going to be shot?

No idea. Depends on if that is the problem which is not proven at this point. We've seen a couple that were able to be used after and a few that are not.

 

[Weasellee]

No idea. Depends on if that is the problem which is not proven at this point. We've seen a couple that were able to be used after and a few that are not.

Opinion. Safe to keep driving in front wheel drive?

 

[JMT]

Ok

Video attached for audio purposes only. Listening for the steady thump thump. Rhythmic and consistent with speed changes.
Ben’s deployment build. When he got back to VA with his Rubicon it started making a noise. After much chasing ($$) and finally driving with microphones attached to the driveline we are pretty sure the “noise” is coming from the rear output of the transfer case.
241J Rubicon
Fluid is good
With rear driveshaft removed and driving in front wheel drive no noise.
It’s not the rear axle. Had it apart already.
It’s not the new Woods driveshaft, had it checked at local driveline shop.
Before I buy a replacement is this one fixable?
Is it ok to drive? Something’s gonna let loose eventually

What do you think about him driving it back to NY in front wheel drive so I can pull and rebuild?

Shoot



TYIA


B

https://share.icloud.com/photos/05d9dxb1CKNHqWo0bQTpidKQA

Hope this works. I’ve never uploaded to YouTube but I will figure it out.

I spent the last 20 min trying to find a video I made that sounds remarkably like yours. Under load, increased with speed. I took the TCase apart and replaced the output seal. I had Adams test the rear driveshaft. They replaced a ujoint. Said the rest was good. I swapped rear axle shafts, checked bearings in diff, checked pre-load on pinion. Thought I was going to go crazy.

It was the driveshaft. I thought it was good because Adam’s tested it and replaced a u joint. Wrong! It was the assumption that mislead me. I rebuilt it and it was perfect again.

 

[mrblaine]

Opinion. Safe to keep driving in front wheel drive?

If the tone ring is loose in the tail housing, you can't stop it from turning in 4 hi so it can possibly eat through the tail housing which can start pumping fluid out. Unless we know one way or another, I don't think I would risk it.

 

[hosejockey61]

Maybe @hosejockey61 has ran in to this before? TYIA

The only way to find out is to open up the case.

 

[macleanflood]

Easily said. I’m in NY he’s stationed in Norfolk Va. I have tools he has some. I’d rather not tow it. If we think it’s rebuildable then we can pay someone there or tow it home or drive it in front wheel drive or

You're talking about a 3/4" socket to drop the skid pan after taking the 13mm transmission mount bolts off. It would help to support the transmission bellhousing with a jack. Then 8mm / 5/16 for the driveshafts. I believe the linkage snaps off...I have a cable shifter so it's just a pin. Then six 15mm nuts around the transfer case...a ratcheting box wrench makes it easy. Drain the fluid if you want. It's a bit of a bench press but it's completely doable.

I'd do it any day of the week, in a parking lot or at night, in the rain on gravel.

-Mac

 

[mrblaine]

You're talking about a 3/4" socket to drop the skid pan after taking the 13mm transmission mount bolts off. It would help to support the transmission bellhousing with a jack. Then 8mm / 5/16 for the driveshafts. I believe the linkage snaps off...I have a cable shifter so it's just a pin. Then six 15mm nuts around the transfer case...a ratcheting box wrench makes it easy. Drain the fluid if you want. It's a bit of a bench press but it's completely doable.

I'd do it any day of the week, in a parking lot or at night, in the rain on gravel.

-Mac

Not for nothing but I'd be very interested in seeing you bench the 241 up like you did the 231. There is a considerable difference in size, balance, and weight. FYI, the nuts on the studs are not 15mm, they are in fact 9/16" since they thread onto 3/8-24 threaded studs.

 

[hosejockey61]

Not for nothing but I'd be very interested in seeing you bench the 241 up like you did the 231.

I've done it, but it ain't fun.

 

[mrblaine]

I've done it, but it ain't fun.

I know it can be done, it just won't be done by most the way he tossed that 231 up there.

 

[mrblaine]

Opinion. Safe to keep driving in front wheel drive?

Thinking about this some more. If it isn't making ANY noise with the rear shaft pulled, I might risk it.