Can you identify that rattle?

[adsm08]

OK, differential diagnosis:

How do I decide between
A) Throw out bearing is bad
B) Something wacky is rattling on the underside

Rattle is definitely louder on the passenger side when I'm looking down at the starter.

When I was under there on the driver side looking up at the bellhousing, it *seemed* quieter.

I think I'm set on doing this clutch kit anyways, since I just bought a transmission jack, but how do I check for what @Uncle Gump was talking about?

Well, if you are set on doing the clutch the throw out bearing should be replaced while you are there anyway, and will come in a decent clutch kit. So that's solved.

The starter issue Uncle Gump was talking about can be tested during the clutch service as well. Once it is out, just tip it back and forth. The gear should NOT move along it's shaft when you do that.

After that... it's really just hitting things and seeing what moves/makes noise.

 

[Uncle Gump]

Yeah sorry... I meant to reply.

adsm08 pretty much explained it. The starter drive gear should be stationary until the starter spins and pushes it out. If the drive gear moves up and down the armature shaft... it's bad.

 

[RJMacReady]

Thanks guys! I will definitely take a look when I have everything apart.

 

[Uncle Gump]

Honestly... I would pull the starter first and check it.

 

[RJMacReady]

That seems like a good idea.

OK, I got one more dumb question for you. Where is my jack point on the front? On the back I just went under the rear differential, but I can't figure out a good spot to lift her in the front.

 

[Dirtman]

Under the control arm/radius arm at the ball joint should be sufficient,

 

[RJMacReady]

It's totally not the throwout bearing. Parked facing down on a steep hill today and there was no noise at all pushing the clutch in and out a bunch, totally normal sounding.

I'm going to look at my starter when I get jacked up later today.

 

[RJMacReady]

Seemed like it was related because pushing on the clutch does change the characteristics of how the transmission is vibrating, and so that must affect how anything rattling against it sounds.

 

[RJMacReady]

I got under there today!

Rattle is absolutely coming from the transfer case at the rear of the transmission, not the starter/bell housing area..

That makes sense because previous owner told me there were problems with the 4 HI.

 

[RJMacReady]

Transfer case is a Borg-Warner 13-50. Following the instructions in one of my manuals, I opened up the check/fill plug (the higher one of the two) to check the fluid level and fluid started pouring out. I assume filling beyond the fill line is probably bad?

 

[4x4junkie]

A little bit beyond the fill line isn't an issue, but way beyond (by like a quart or more) would probably cause issues.

Was the fluid condition OK (reddish to reddish-brown color)? It wasn't silver or metallic-looking was it?

 

[RJMacReady]

I kind of hustled to put the plug back in before the stuff got all over the driveway so I'm not totally sure how over full it was. Feels like about a half cup or so came out before I got the plug back in. I figured I may as well change it while I'm screwing with it since the cars over 100k miles and idk if owner did it.

Looked a nice pink color, it didn't seem messed up to me.

Also I take it back, I have to say I can't tell where that damn rattle/grind is coming from. I turned it on again and it seems like it could be anywhere from the case up to the bell housing. It's really hard to tell!

 

[Dirtman]

Did you take that jar of baby teeth out yet?

 

[RJMacReady]

I solved it. I mentioned it in the main thread for doing my clutch change but just to explain here for future forum searchers: This sound was loose bolts on transmission and starter mount.

EDIT: OK There's a second rattle actually. Tightening the bolts fixed the rattle that you can hear when the truck is idling. There is a second rattle that seems to change its sound with throttling. I'll update this thread when I finally diagnose it.