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DCDAD

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My x-fer case is clunking!! HELP!

Hi Guys, it's been a while since I've been able to visit DOC, work has been very demanding lately.

Anyway, I took my daughter four wheeling last weekend out to a off road park here in Cali. To have fun with her, and to see how the D would handle the dirt and small hills this place had. This is the first time my D has been in 4hi since I bought her little over a year ago, I was having flashbacks of the fun times I used to have with my 72' power wagon muddin, climbing pretty much whatever I threw in front of it.

My intention was to be a lot more kind to the D as it's not a $200 power wagon, it's my daily driver. So we get to the park and enter into the dirt/sandy hilly etc. I switched the selector to 4hi and the light on the switch glowed steady. Ready to go right? Wrong!! This god awful gear stripping broken teeth clanking noise was coming from under big earl (come on, you know you have a name for your D too) so the trip was cut short! Put her back into 2wd and the noise goes away.

When we got home, I put it up on jack stands at all four corners to see if I could duplicate this horrid sound. When it's in 4hi, at an idle, in drive, all wheels roll. When I step on the brake, the popping, clanking sound rears its ugly head! I had my wife get into earl and do it again and the sound is definitely coming from the x-fer case.

Does somebody have an exploded view of a x-fer case I could look at? Any and all input or help would be greatly appreciated. Thanks to all in advance!! Ron
 
I guess you have a switch instead of a stick. Engaging 4X4 while rolling in neutral at 2-3mph provides the smoothest shift?sometimes you need to reverse maybe 20 feet and stop to engage. Loud clunking is sometimes heard. In my experience, anyway.
 
Yep, you need to be moving to engage the transfer case. If you attempt to do it in park it'll growl like hell.

greg
 
Hello DC,
I'm not sure guys, I think he has a problem. I have an 01' SLT with the switch selector and never hear a problem when I switch it into 4HI while in Park or driving up to speeds 55MPH max and switching to 4HI.
I do know you're suppose to either be stationary in neutral or going only a couple MPH in neutral when going into 4LO and max speed only up to 25MPH.
Joe
 
I agree it sounds like something isn't meshing in there. Possibly the solenoid which engages the 4wd isn't making it all the way in and only partially engaging the transfer case??
I really can't believe he's having trouble since his D is Sierra Bronze and those are known (at least in my house ) to be better than other colored D's. J/K LOL
Let us know how you make out!
Steve
DOC Pres
 
I'd try the shifting into 4 hi while driving first, If no noise is heard from there, you should be OK, If you still hear the noise, You might have a strecthed x-fer case chain.
 
earl

You didn't do anything wrong? 4 hi is proper selection for the terrain. But something isn't right in the Xfer case. It's a chain driven system that's normally very robust. I'd get a 4x4 shop to look at earl. He's knashing teeth for some reason. Is the fluid level OK? Has it been serviced regularly? It takes a little over 1 qt of Mopar ATF 4 as lubrication.

The good news is that all 4 wheeels are turning. Maybe it's not too serious? I hope.

Bill
 
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