Grinding transfer case

[75cruzin]

Ok guys have this grinding crunching sound coming from the transfer case .
1-1st gear low range going down hill only
2- near new front tail sharft
3- tested with old front tail sharft ( noise still there
4- uni joints are good.cleaned and greased
5- NO noise when just in 2wd

Going to pull out the transfer case next week end .
Any tips or tricks would be appreciated
And what rebuild kits do you recommend

Thanks

 

[clintnz]

Never had a transfer issue myself but apparently one common issue is the layshaft thrust washers wearing out.

I rebuilt mine a while back when I installed some lower gears. Used a Terrain Tamer kit which worked fine, Koyo bearings same as OEM. You can't take the transfer off as a unit, it has to be disassembled to get it off the gearbox. We actually pulled out the transfer & gearbox together as by the time you have everything unbolted from the transfer you are 95% of the way to having the gearbox out also & the transfer is much easier to assemble onto the gearbox with it standing on end. We had the luxury of a hoist & a proper trans jack though. Superglue the layshaft thrust washers in place so they are in the right spot for re-assembly.

Cheers
Clint