Builds 1990 LJ78 in Montana (6 Viewers)

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Is this with the hubs locked or unlocked? Sounds like something is skipping teeth to me, maybe the shift sleeve isn't engaging fully and is skipping under load?
 
Is this with the hubs locked or unlocked? Sounds like something is skipping teeth to me, maybe the shift sleeve isn't engaging fully and is skipping under load?
This happens in both 4h and 4l, when the hublocks are engaged.

TChublocksclunk
4hlockedyes
4llockedyes
2wdlockedno
4hunlockedno
4lunlockedno
2wdunlockedno
 
With hubs locked and transfer case in 4WD you'll experience drivetrain binding on hard surfaces like pavement. Can be hard on components, but shouldn't cause immediate damage, especially not when driving straight. Have you been able to confirm the front drive sleeve fully engages?

The switches on the transfer should only be there for the neutral and 4wd indicator lights at this point.
 
I've had a complete front-end rebuild at this point, but I'm not familiar with the front-drive sleeve. Is that the part that engages the TC input shaft to the trans? We did seals and bearings in the TC but not the input-shaft. Is there a way for me to test it without tearing it all apart?
 
With hubs locked and transfer case in 4WD you'll experience drivetrain binding on hard surfaces like pavement. Can be hard on components, but shouldn't cause immediate damage, especially not when driving straight. Have you been able to confirm the front drive sleeve fully engages?

The switches on the transfer should only be there for the neutral and 4wd indicator lights at this point.
oh do you mean the free-wheeling hub in the hublocks?
 

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