T-Case problem?

[johnsonsnb]

Hi folks,

I'm trying to troubleshoot a problem that I'm having with my '93 4x4. The other day, I came to a corner, and downshifted. I loud grinding noise came from the drivetrain. I stopped the truck, and then shifted it back into 1st, and away I went again.

Then, the other night, I was going down a hill, and then there was a clunk and hesitation in the driveline. I let off on the throttle, and the grinding started again.

I did some checking today. The u-joints are OK, and nothing seems to be abnormal under the truck.

I first thought it to be the clutch, but there is no problem shifting the transmission. Then, I started thinking that perhaps the t-case might be having problems. I took a drive this evening, and 2wd, 4lo, and 4hi is working.

By the way, the t-case is an electric, and the transmission is a 5sp manual.

Thoughts? recommendations?

Thanks in advance!

 

[kkjb4x4.0]

Do u still have the automatic hubs? Befor I changed mine for manuals, mine would klunk and klick around corners on the road in 2 wd. Take them off , clean and lubricate them , it may well be ur problem unless u know for sure the noise is coming from somewhere else.

 

[MAKG]

Are you sure the rear end is good?

It sounds to me (please correct) like you get the problem only while coasting in gear. If so, it has to be a loose gear somewhere. Perhaps the rear end, perhaps the transmission. I suppose it could be the transfer case, but I kinda doubt it.

UNLESS the transfer case shifts on its own (due to a short perhaps?) into low range.

 

[johnsonsnb]

Update

Thanks for the replies.

To answer your questions:

- Mine has manual hubs.
- Coasting in gear; yes, that is correct. Good point, it could be the diff., trans, or t-case.

I'm in the process of locating a used t-case, and going to try that out. I had read elsewhere that the grinding noise that I'm getting is possibly the t-case, and the forks are trying to shift the case in/out when power is not applied.

But I like your idea. It's not a big deal to pull the cover off the diff, and see if there's any stray metal.

I'll keep you posted. Any other ideas are welcome!

 

[johnsonsnb]

New update

Hi folks,

Well, the Ranger is back on the road. As it turns out, it was the transfer case. I picked up a salvage one, and installed it. Seems to have cured it.

A couple of observations:

1) After I had the old one out, I held the input shaft to the t-case, and was able to spin the output shaft (rear that is). The t-case was in 2WD. The grinding noise was present. Ouch! I might get some time in the next week or so to pull it apart, and inspect the damage. When I do, I'll post the pics.

2) I drained the oil from it. I had changed it about a year and a half ago. Seems that it should have been done earlier. The clean red MERCON had changed color to a brown/tan. I don't do any water fording, so I'm assuming it must have been some of the organic particles in the t-case?

Moral of the story.... If you havn't changed the oil in your t-case lately, take the time and do it.

Thanks for all the help folks!

 

[oystein]

I might have the same problem.

Just have some questions:
If "coasting in gear" means rolling downhill in gear with throttle off. When I do so I can hear a clunck in drivetrain when the drivetrain tights up, - than grinding. Grinding disappears if I clutch in or keeps throttle on.

I earlier also had a gearing problem, so have just changed pilot bearing, clutch slave and input bearing. Thought it was the same problem

When I look at the transfer case holding the input shaft, I can do some movements in the output shaft 30 degrees or so....

 

[oystein]

Yesterday I unbolted the rear driveshaft, and tried driving with only front shaft. Same grinding sound. Looks like the gearbox/transfer falls out of gear.

 

[oystein]

I have just opened the transfer. The oil pump hose was broken and shift fork completely worn out allowing the gear hub to move out of gear.

Checked price for a used BW 1354, - 900-1000$ here in Norway. Think I have to try to rebuild mine before buying one of those...

 

[BlackBII]

I have just opened the transfer. The oil pump hose was broken and shift fork completely worn out allowing the gear hub to move out of gear.

Checked price for a used BW 1354, - 900-1000$ here in Norway. Think I have to try to rebuild mine before buying one of those...

Ouch. I have a few extra...how much would shipping be from Utah, US to over there?