What’s wrong with this transfer case?

Active duty on a base parking lot with a basic socket set. It has the Savvy TT so many bolts just for the skid. And then where does he tear apart the case? On the ship in his rack? Trust me I’d pull it too but he’s in a different situation.
 
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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.

I hear ya. 3k on a new Woods shaft that was tested at a driveline shop. Monday I will speak to the tech that did the driving test with the microphones attached.
 

8 bolts to remove and then rebuild for relatively cheap. Could not replicate it by putting the rear on jack stands and running it. We put my phone on the ground in the street and slow mo setting and drove over it. It was unquestionably right at the TCase output area where the thudding was the loudest. It really narrowed down the search. By that time I’d already replaced the TCase output bearing, so it had to be the shaft. Like yours if I removed the rear driveshaft the sound went away. Was driving me crazy. Then I got mad at Adams when I found out they didn’t catch the bad ujoint. I replaced the centering ball too, but I think it was a ujoint IIRC.
 
8 bolts to remove and then rebuild for relatively cheap. Could not replicate it by putting the rear on jack stands and running it. We put my phone on the ground in the street and slow mo setting and drove over it. It was unquestionably right at the TCase output area where the thudding was the loudest. It really narrowed down the search. By that time I’d already replaced the TCase output bearing, so it had to be the shaft. Like yours if I removed the rear driveshaft the sound went away. Was driving me crazy. Then I got mad at Adams when I found out they didn’t catch the bad ujoint. I replaced the centering ball too, but I think it was a ujoint IIRC.

I actually thought I read through your thread on this and you said you had squeaky grinding is that not correct? Was that a different thread?
 
8 bolts to remove and then rebuild for relatively cheap. Could not replicate it by putting the rear on jack stands and running it. We put my phone on the ground in the street and slow mo setting and drove over it. It was unquestionably right at the TCase output area where the thudding was the loudest. It really narrowed down the search. By that time I’d already replaced the TCase output bearing, so it had to be the shaft. Like yours if I removed the rear driveshaft the sound went away. Was driving me crazy. Then I got mad at Adams when I found out they didn’t catch the bad ujoint. I replaced the centering ball too, but I think it was a ujoint IIRC.

Did you choose to rebuild the driveshaft because there was nothing left to do?
 
Did you choose to rebuild the driveshaft because there was nothing left to do?

Yes.
I actually thought I read through your thread on this and you said you had squeaky grinding is that not correct? Was that a different thread?

Different thread or different occasion, but I don’t remember having a squeaky grinding. 🙂

P.s. that sound is rotational AND under load. I suspect that putting the shaft on a machine is not putting the ‘kind’ of load we are putting it under in the driveline with wheels on the ground, and that was my conclusion to why Adams missed it, especially since I could not replicate it with wheels off the ground. Jack the rear axle up and put on Jack stands and see if you can replicate.
 
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Active duty on a base parking lot with a basic socket set. It has the Savvy TT so many bolts just for the skid. And then where does he tear apart the case? On the ship in his rack? Trust me I’d pull it too but he’s in a different situation.

If he's on base isn't there an auto shop? There was on most of the bases I was on... And some had parking if your vehicle was inop for a few days or weeks.
I did an engine swap & installed a lift kit in one.
 
If he's on base isn't there an auto shop? There was on most of the bases I was on... And some had parking if your vehicle was inop for a few days or weeks.
I did an engine swap & installed a lift kit in one.

There is and he has done brakes and oil changes there. The hours are not super convenient and they don’t like multi-day projects at all. But he will pull it if necessary, tools are also an issue.
 
There is and he has done brakes and oil changes there. The hours are not super convenient and they don’t like multi-day projects at all. But he will pull it if necessary, tools are also an issue.

Must not be a fully stocked MWR Auto Shop like I'm used to. They had a toolbox you could sign out and use plus a load of special tools. They had a lot inside the fence for long term projects that might not be drivable. They also had 2-3 bays for 3-5 day project that you could reserve. I had a YJ when I was @ Ft Ord, CA and had to rebuild the 4.0 in it. So pulled the engine and pushed it outside while the engine was being rebuilt. then pushed it back in when it was ready.
 
Ok. Two short videos if i can.

1st video rotating back and forth with t-case in 4wd

https://share.icloud.com/photos/008r8RsXKMt0qyxb55xXs8Sgg

2nd video same movement with t-case in 2wd.

https://share.icloud.com/photos/0febVZD8vH-PkE_MFWqllKoXQ

We think he is repeating the sound in 2wd.

And the driveshaft is in really good condition.

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