Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
usual. Mostly dirt with some serious mud holes but no rocks to stress
things. Managed to break the vacumn switch on the transfer case, fixed
that, went to check out the 4wd. As soon as I put ANY load on the
transfer case in 4wd, I got some NASTY 'bangs' from the trasfer case.
Once a second, several times. Felt like something was not engaging
right. Pulled the case, fluid was low, chain was very sloppy. Nothing
else seems to be seems to be chewed up: front axle 'U' joints look ok,
front axle disconnect dog looks fine, transfer case synchos look ok.

Question: would a loose chain give me the noise or should I look for
something more?? The chain just barely misses the side of the case when
pushed over.

 

Had same. Chain is stretched and is jumping on the sprocket. Check gears
and replace if show wear. Replace chain. Replace all bearings. Failure to
do this will result in catastrophic failure of the T-Case.

Scott
"RoyJ" <spamless@microsoft.net> wrote in message
news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
> Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
> usual. Mostly dirt with some serious mud holes but no rocks to stress
> things. Managed to break the vacumn switch on the transfer case, fixed
> that, went to check out the 4wd. As soon as I put ANY load on the transfer
> case in 4wd, I got some NASTY 'bangs' from the trasfer case. Once a
> second, several times. Felt like something was not engaging right. Pulled
> the case, fluid was low, chain was very sloppy. Nothing else seems to be
> seems to be chewed up: front axle 'U' joints look ok, front axle
> disconnect dog looks fine, transfer case synchos look ok.
>
> Question: would a loose chain give me the noise or should I look for
> something more?? The chain just barely misses the side of the case when
> pushed over.

 

Had same. Chain is stretched and is jumping on the sprocket. Check gears
and replace if show wear. Replace chain. Replace all bearings. Failure to
do this will result in catastrophic failure of the T-Case.

Scott
"RoyJ" <spamless@microsoft.net> wrote in message
news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
> Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
> usual. Mostly dirt with some serious mud holes but no rocks to stress
> things. Managed to break the vacumn switch on the transfer case, fixed
> that, went to check out the 4wd. As soon as I put ANY load on the transfer
> case in 4wd, I got some NASTY 'bangs' from the trasfer case. Once a
> second, several times. Felt like something was not engaging right. Pulled
> the case, fluid was low, chain was very sloppy. Nothing else seems to be
> seems to be chewed up: front axle 'U' joints look ok, front axle
> disconnect dog looks fine, transfer case synchos look ok.
>
> Question: would a loose chain give me the noise or should I look for
> something more?? The chain just barely misses the side of the case when
> pushed over.

 

Had same. Chain is stretched and is jumping on the sprocket. Check gears
and replace if show wear. Replace chain. Replace all bearings. Failure to
do this will result in catastrophic failure of the T-Case.

Scott
"RoyJ" <spamless@microsoft.net> wrote in message
news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
> Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
> usual. Mostly dirt with some serious mud holes but no rocks to stress
> things. Managed to break the vacumn switch on the transfer case, fixed
> that, went to check out the 4wd. As soon as I put ANY load on the transfer
> case in 4wd, I got some NASTY 'bangs' from the trasfer case. Once a
> second, several times. Felt like something was not engaging right. Pulled
> the case, fluid was low, chain was very sloppy. Nothing else seems to be
> seems to be chewed up: front axle 'U' joints look ok, front axle
> disconnect dog looks fine, transfer case synchos look ok.
>
> Question: would a loose chain give me the noise or should I look for
> something more?? The chain just barely misses the side of the case when
> pushed over.

 

Sprockets (gears) look good, chain will be replaced, I suspect the chain
was not hopping the teeth, merely climbing up on them and slaming down
in the correct spot. Only did it for perhaps a dozen to two dozen hits
as I tried various things to diagnos the trouble.

reconair wrote:
> Had same. Chain is stretched and is jumping on the sprocket. Check gears
> and replace if show wear. Replace chain. Replace all bearings. Failure to
> do this will result in catastrophic failure of the T-Case.
>
> Scott
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
>
>>Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
>>usual. Mostly dirt with some serious mud holes but no rocks to stress
>>things. Managed to break the vacumn switch on the transfer case, fixed
>>that, went to check out the 4wd. As soon as I put ANY load on the transfer
>>case in 4wd, I got some NASTY 'bangs' from the trasfer case. Once a
>>second, several times. Felt like something was not engaging right. Pulled
>>the case, fluid was low, chain was very sloppy. Nothing else seems to be
>>seems to be chewed up: front axle 'U' joints look ok, front axle
>>disconnect dog looks fine, transfer case synchos look ok.
>>
>>Question: would a loose chain give me the noise or should I look for
>>something more?? The chain just barely misses the side of the case when
>>pushed over.
>
>
>

 

Sprockets (gears) look good, chain will be replaced, I suspect the chain
was not hopping the teeth, merely climbing up on them and slaming down
in the correct spot. Only did it for perhaps a dozen to two dozen hits
as I tried various things to diagnos the trouble.

reconair wrote:
> Had same. Chain is stretched and is jumping on the sprocket. Check gears
> and replace if show wear. Replace chain. Replace all bearings. Failure to
> do this will result in catastrophic failure of the T-Case.
>
> Scott
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
>
>>Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
>>usual. Mostly dirt with some serious mud holes but no rocks to stress
>>things. Managed to break the vacumn switch on the transfer case, fixed
>>that, went to check out the 4wd. As soon as I put ANY load on the transfer
>>case in 4wd, I got some NASTY 'bangs' from the trasfer case. Once a
>>second, several times. Felt like something was not engaging right. Pulled
>>the case, fluid was low, chain was very sloppy. Nothing else seems to be
>>seems to be chewed up: front axle 'U' joints look ok, front axle
>>disconnect dog looks fine, transfer case synchos look ok.
>>
>>Question: would a loose chain give me the noise or should I look for
>>something more?? The chain just barely misses the side of the case when
>>pushed over.
>
>
>

 

Sprockets (gears) look good, chain will be replaced, I suspect the chain
was not hopping the teeth, merely climbing up on them and slaming down
in the correct spot. Only did it for perhaps a dozen to two dozen hits
as I tried various things to diagnos the trouble.

reconair wrote:
> Had same. Chain is stretched and is jumping on the sprocket. Check gears
> and replace if show wear. Replace chain. Replace all bearings. Failure to
> do this will result in catastrophic failure of the T-Case.
>
> Scott
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
>
>>Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
>>usual. Mostly dirt with some serious mud holes but no rocks to stress
>>things. Managed to break the vacumn switch on the transfer case, fixed
>>that, went to check out the 4wd. As soon as I put ANY load on the transfer
>>case in 4wd, I got some NASTY 'bangs' from the trasfer case. Once a
>>second, several times. Felt like something was not engaging right. Pulled
>>the case, fluid was low, chain was very sloppy. Nothing else seems to be
>>seems to be chewed up: front axle 'U' joints look ok, front axle
>>disconnect dog looks fine, transfer case synchos look ok.
>>
>>Question: would a loose chain give me the noise or should I look for
>>something more?? The chain just barely misses the side of the case when
>>pushed over.
>
>
>

 

All I ended up doing with mine was replacing the chain, the input and output
bearings and the shift mode fork. I let the fluid level get too low for too
long. I put another 150K miles on it after the repair and eventually used
it as a core trade for a REMAN with a SYE.

Scott
"RoyJ" <spamless@microsoft.net> wrote in message
news:tsEsg.5835$PE1.605@newsread2.news.pas.earthli nk.net...
> Sprockets (gears) look good, chain will be replaced, I suspect the chain
> was not hopping the teeth, merely climbing up on them and slaming down in
> the correct spot. Only did it for perhaps a dozen to two dozen hits as I
> tried various things to diagnos the trouble.
>
> reconair wrote:
>> Had same. Chain is stretched and is jumping on the sprocket. Check
>> gears and replace if show wear. Replace chain. Replace all bearings.
>> Failure to do this will result in catastrophic failure of the T-Case.
>>
>> Scott
>> "RoyJ" <spamless@microsoft.net> wrote in message
>> news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
>>
>>>Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
>>>usual. Mostly dirt with some serious mud holes but no rocks to stress
>>>things. Managed to break the vacumn switch on the transfer case, fixed
>>>that, went to check out the 4wd. As soon as I put ANY load on the
>>>transfer case in 4wd, I got some NASTY 'bangs' from the trasfer case.
>>>Once a second, several times. Felt like something was not engaging right.
>>>Pulled the case, fluid was low, chain was very sloppy. Nothing else seems
>>>to be seems to be chewed up: front axle 'U' joints look ok, front axle
>>>disconnect dog looks fine, transfer case synchos look ok.
>>>
>>>Question: would a loose chain give me the noise or should I look for
>>>something more?? The chain just barely misses the side of the case when
>>>pushed over.
>>
>>

 

All I ended up doing with mine was replacing the chain, the input and output
bearings and the shift mode fork. I let the fluid level get too low for too
long. I put another 150K miles on it after the repair and eventually used
it as a core trade for a REMAN with a SYE.

Scott
"RoyJ" <spamless@microsoft.net> wrote in message
news:tsEsg.5835$PE1.605@newsread2.news.pas.earthli nk.net...
> Sprockets (gears) look good, chain will be replaced, I suspect the chain
> was not hopping the teeth, merely climbing up on them and slaming down in
> the correct spot. Only did it for perhaps a dozen to two dozen hits as I
> tried various things to diagnos the trouble.
>
> reconair wrote:
>> Had same. Chain is stretched and is jumping on the sprocket. Check
>> gears and replace if show wear. Replace chain. Replace all bearings.
>> Failure to do this will result in catastrophic failure of the T-Case.
>>
>> Scott
>> "RoyJ" <spamless@microsoft.net> wrote in message
>> news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
>>
>>>Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
>>>usual. Mostly dirt with some serious mud holes but no rocks to stress
>>>things. Managed to break the vacumn switch on the transfer case, fixed
>>>that, went to check out the 4wd. As soon as I put ANY load on the
>>>transfer case in 4wd, I got some NASTY 'bangs' from the trasfer case.
>>>Once a second, several times. Felt like something was not engaging right.
>>>Pulled the case, fluid was low, chain was very sloppy. Nothing else seems
>>>to be seems to be chewed up: front axle 'U' joints look ok, front axle
>>>disconnect dog looks fine, transfer case synchos look ok.
>>>
>>>Question: would a loose chain give me the noise or should I look for
>>>something more?? The chain just barely misses the side of the case when
>>>pushed over.
>>
>>

 

All I ended up doing with mine was replacing the chain, the input and output
bearings and the shift mode fork. I let the fluid level get too low for too
long. I put another 150K miles on it after the repair and eventually used
it as a core trade for a REMAN with a SYE.

Scott
"RoyJ" <spamless@microsoft.net> wrote in message
news:tsEsg.5835$PE1.605@newsread2.news.pas.earthli nk.net...
> Sprockets (gears) look good, chain will be replaced, I suspect the chain
> was not hopping the teeth, merely climbing up on them and slaming down in
> the correct spot. Only did it for perhaps a dozen to two dozen hits as I
> tried various things to diagnos the trouble.
>
> reconair wrote:
>> Had same. Chain is stretched and is jumping on the sprocket. Check
>> gears and replace if show wear. Replace chain. Replace all bearings.
>> Failure to do this will result in catastrophic failure of the T-Case.
>>
>> Scott
>> "RoyJ" <spamless@microsoft.net> wrote in message
>> news:f9Csg.6022$ye3.2157@newsread1.news.pas.earthl ink.net...
>>
>>>Went wheeling my '87 YJ a couple weeks ago, pushed it a bit more than
>>>usual. Mostly dirt with some serious mud holes but no rocks to stress
>>>things. Managed to break the vacumn switch on the transfer case, fixed
>>>that, went to check out the 4wd. As soon as I put ANY load on the
>>>transfer case in 4wd, I got some NASTY 'bangs' from the trasfer case.
>>>Once a second, several times. Felt like something was not engaging right.
>>>Pulled the case, fluid was low, chain was very sloppy. Nothing else seems
>>>to be seems to be chewed up: front axle 'U' joints look ok, front axle
>>>disconnect dog looks fine, transfer case synchos look ok.
>>>
>>>Question: would a loose chain give me the noise or should I look for
>>>something more?? The chain just barely misses the side of the case when
>>>pushed over.
>>
>>