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Transfer Case 4Lo Problems. Anyone opened one up?

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Old 05-21-2012, 04:49 PM   #1
96Taco [OP] 96Taco is offline
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Transfer Case 4Lo Problems. Anyone opened one up?

Hi guys,

I've noticed on my vehicle when in 4 Lo I get a metal on metal grinding noise. 2H or 4H are all good. Just sucks riding the clutch on the trails in 4H instead of listening to grinding in 4Lo.
I have shift stick 4WD with ADD. w/o one touch 2-4 selector as the fsm calls it.

I've never opened a transfer case up before so I do not have a good visual of whats going on in there. I attached one of the diagrams from the fsm which is helpful, but it would be more useful to talk to someone who has had a play with one. Or knows whats going on.

I asked a buddy if it would be a bearing, but he believes all the bearings are always spinning its just weather its engaged or not.. . so you would always hear it grinding if it was. Not sure if thats how it works or not. Sound reminds me of that grinding noise u get from a really bad ujoint i guess.

Here is the diagram.



I looked at rebuild kits and used transfer cases from the scrap yard and both options are very expensive. I would rather just replace or fix the malfunction than throw money at it. I understand without seeing it yourself its almost impossible to diagnose for sure, but any insight would be great.

Thanks guys.
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Old 05-21-2012, 04:52 PM   #2
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Im going to sub to this for future reference
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Old 05-21-2012, 04:53 PM   #3
SNAPPIN NECKS AND CASHIN CHECKS.
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It sounds like it not engaged completely
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Old 05-21-2012, 05:31 PM   #4
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On the diagram I see there is 2 stoppers. One is a shift fork stopper and a input gear stopper. One of these could be the problem alowing a shift fork or gear to move to far thus causing a grinding. these stoppers are held in place by a roll pin and snap ring.
Really hard to tell without driving or listening to it.
There not hard to disassemble just be carefull to not lose or assemble without the springs,pins or ball bearings. Some of these are small parts
Good weekend project for you and a buddy.
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Old 05-21-2012, 08:08 PM   #5
96Taco [OP] 96Taco is offline
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Thanks guys. Hope it is something as easy as not fully engaging or stop pins.

Will report back once I tear in to it and have a good look.
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Old 05-22-2012, 07:04 AM   #6
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The planetary gear at the front is responsible for low range. Even in high range, the gears in the planetary system are turning, the difference is that in high, the output shaft is straight connected to the input shaft through the sun gear, and in low, the output shaft is driven by the planet gear carrier.

What this means is that your problem is either that the shift hub isn't being moved fully into low position, or the gear engaging the output shaft to the planet carrier has been eaten up. Before ripping it apart, please take a look at the shift lever and related components, which you can access from the cab without removing the transfer case.
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Old 05-23-2012, 07:05 AM   #7
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Quote:
Originally Posted by knucklehead View Post
The planetary gear at the front is responsible for low range. Even in high range, the gears in the planetary system are turning, the difference is that in high, the output shaft is straight connected to the input shaft through the sun gear, and in low, the output shaft is driven by the planet gear carrier.

What this means is that your problem is either that the shift hub isn't being moved fully into low position, or the gear engaging the output shaft to the planet carrier has been eaten up. Before ripping it apart, please take a look at the shift lever and related components, which you can access from the cab without removing the transfer case.
Great response. Thankyou! Better understanding of how the 4Lo and Hi work now.

Will tear out the shift lever this weekend and see what I can find. Hope its something easy.
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Old 05-24-2012, 07:42 AM   #8
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Quote:
Originally Posted by knucklehead View Post
The planetary gear at the front is responsible for low range. Even in high range, the gears in the planetary system are turning, the difference is that in high, the output shaft is straight connected to the input shaft through the sun gear, and in low, the output shaft is driven by the planet gear carrier.

What this means is that your problem is either that the shift hub isn't being moved fully into low position, or the gear engaging the output shaft to the planet carrier has been eaten up. Before ripping it apart, please take a look at the shift lever and related components, which you can access from the cab without removing the transfer case.

Is it possible to drive the truck very slowly with the Hi-Lo 2-4 stick removed to try to identify the noise while looking in to the transfer case with a flashlight?

Or will that just splash gear oil everywhere?
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Old 05-24-2012, 10:02 AM   #9
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Could be a little messy? Could throw transfer into gear without a lever if the detents are badly worn. Be carefull!!
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