Transfer Case grinding noise

https://youtube.com/shorts/67p2yTfLHeQ?feature=share3

Seems to happen more after light bumps and turns. You can feel it in the shifter, but moving it around in place after the fact there's nothing. What could the problem be?

BTW I just put this in for a 4x4 swap

 

Nobody has ever heard something like this?

 

My internet sucks when try to watch a You tube post it buffers so much then just quits.

The engine mounts and transmission mounts all good and tight. Did any bolts vibrate loose?

The transfer case shifter bushing and seat in good shape ?

loose exhaust or heat shields vibrating?

Driveline vibration from suspension flexings

Noises and vibrations are so very hard to locate .

Good Luck!

 

Chain slap maybe but I doubt it or I would think you'd hear it consistently. Is it a regular occuring noise or just with bumps/turns as you mentioned?

The clip is way short. Anyway you can do a longer clip? GoPro? If so, maybe secure it under the vehicle close to the tcase and try to reproduce it again.

 

More and more I listen to this I want to say chain slap. Definitely need a longer clip if you can record one.

 

Ya it's just cruising. I cut out just the part where it happened, it's just normal driving noise beyond that. When it happens it's always the same kind of noise and sort of intermittent pulsing like in the video. I did an hour drive that day and it only happened on the 2nd leg of the trip, about 8 times including this vid. This was going about 75 on the freeway

 

On the tranny mount I had to leave a bolt off (1 of 4)because of manufacturing tolerance being off. Can't imagine that's the culprit though... I'll double check the cat heat shield

The shifter bushing, no, bad shape, and the seat I couldn't locate a part # for. I actually bought the wrong one from Toyota. But it doesn't matter if I grab the shifter when it happens, noise and feeling stays the same

 

Doubt it’s chain slap then. It does not sound like a vibration noise but more of a rattle. Double check everything.

 

Maybe disconnect both drive shafts and run the truck threw all the gear options. If it still does it than you at least know it's the case for sure.

 

Actually I don't even have the front driveshaft on there at all since I've been slacking on doing the front wheel bearings, but I can at least stick it in 4hi for a while and see if it still does it

 

It does sound like a chain would though, definitely not ready to rule that out

 

So if its something that occurs with any regularity then consider the chain. In your video you can hear it and then it pauses briefly then again sounds like the same but the vid cuts off. Why I was thinking a longer vid would be nice. Perhaps its only at a certain RPM (you mention it happened roughly 8 times. Chain stretch happens - how often, that I have no idea.

I know with the 95 transfer case I have here, when I cracked it open you can definitely see where the chain was hitting the inside of the case. Why it was hitting, I have no idea. When I rebuilt the guts, I opted to re-use the chain. No issues and no out of place noises. The chain can still be ordered but its a few hundred dollars iirc.

 

Yikes. I only paid $200 for the whole thing and the warranty is over