FJ60 Drivetrain Noise

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M

mountainibis

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I’m trying to diagnose a weird sound my 60 is making. Drivetrain is completely stock. The noise doesn’t change at different speeds. When driving down the road, it’s most noticeable in 4th gear at 45-50 mph when either barely on or just off the accelerator. It’s kind of a high pitched metallic squeal.

With the rear driveshaft removed, vehicle in 2 high, fourth gear, and a little throttle, it will make more of a ‘bearing-y’ growling noise. I put a long screwdriver between my ear and the transfer case while it was running without the driveshaft and it’s much louder at the transfer case than the tranny or anywhere else.

I rebuilt the transfer case and replaced the clutch less than 100 miles after buying . I’ve driven about 2000 miles since then, and the noise keeps getting worse.

From what I can tell, it only happens in 4th gear. The noise is the same whether in 4 lo, 4 hi, neutral, or 2 hi.

Does this sound like a problem with the transmission? Transfer case? Something else?

Thanks in advance for any thoughts, insight, comments, or snide remarks.
 
did you check the oil levels? trans and transfer
any movement in the output flange?
drained the oil into separate containers checking for metal bits?
 
Thanks for the reply. Both tranny and trans oil levels are where they should be. No movement on the t-case output flange.

Tranny oil was clean when I drained and refilled during the t-case rebuild. I haven’t drained either since then, which was about 2,000 miles ago.
 
When you did the clutch did you replace the Throw out bearing? Sounds like it may be going bad.

Could also be the Output shaft of the transmission need to be tightened up on the transfer case. You could drain and carefully remove the seal to verify and check. It would mean something came loose (stake nut?) and is getting more play.
 
Throw-out bearing was replaced along with the clutch, pilot bearing, etc.

The stake nut on the rear t-case output shaft looks like it hasn’t moved.

I’ll try to get some audio of the noise and figure out how to get it posted.

What kind of noise would a thrust washer on the idler shaft make if it wasn’t seated properly?
 
I think @NookShneer is referring to the stakenut behind the cover, not the one on the flange. The output shaft of the transmission.
 
Gotcha. Now I’m worried. It’s been almost a year ago since the rebuild, but I don’t remember staking a nut on that shaft. :oops: I guess the back half of the case is coming off regardless. May be awhile before I can get to it, but I’ll report back with any updates.

Thanks for the help!
 
Four months later, I finally have time to investigate.

Drained the transfer case oil. It was nasty - black with metal flecks in it (only 2000 miles on it). Refilled with 90-140 just to limp it to the shop for inspection. No changes to the noise.

Output shaft was staked. Thrust washer was well within tolerance spec.

Dropped transmission and transfer case and disassembled transfer case on the work bench. The only thing I could find was a groove in the backing plate of the case where the tranny output shaft bearing seats.

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The groove would be between 9 and 1 o’clock if you’re looking at the back of the transmission. It’s weird that this is the only thing that looks amiss, but it’s on the tranny side of the deal, and it’s the transfer case oil that was black.

All that said, is there anything else I should check? Is there anything that could cause this aside from screwing something up when I reassembled the transfer case? If this is the only thing wrong, what should be done to repair the damage?

Thanks in advance for any help.
 
OK, so I reassembled everything, making sure the rear transmission bearing was seated all the way into the transfer case housing. Still makes the noise. Starting to wonder if it’s a transmission issue.

Anyone have any guesses? Noise is loudest in fourth gear, 45 mph or so, with light throttle.



Don’t mind the dirty carpet and loose shift boot. :hillbilly:
 
That doesn't sound like any noise I've ever heard coming from a transfer case or transmission.
Clueless on what it could be.
:beer:
 
I’ve never rebuilt one of these transfer cases but I’m wondering if maybe the gear lash could be wrong?
 
Seth S said:
Ok. I suspected that was the case but the sounds being emitted made me think of gears whining when the lash is not correct.
Click to expand...
I have low range gears, they whine ( urggg...drives me nuts! )
This noise he has is not that. But I am unable to help with that noise, I can’t seem to hear
it myself from the video. Wish I could.
 
cruiserpilot said:
I have low range gears, they whine ( urggg...drives me nuts! )
This noise he has is not that. But I am unable to help with that noise, I can’t seem to hear
it myself from the video. Wish I could.
Click to expand...

Are your low range gears straight cut? straight cut are usually cheaper to make but they are also super noisy.
 
Now that gears are mentioned, it’s got me thinking. If the vehicle was driven with a dry transfer case, could it have caused damage to the gears that would cause that noise?

When I bought the vehicle, I was excited that it didn’t leak a lot. That excitement lasted until I drained the t-case and only about a cup of oil came out. Filled it back up and it leaked like a sieve after driving it. That led to the case rebuild.
 
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