Help with transfer case woes (1 Viewer)

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Jun 13, 2011
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Driving to work this morning and all of a sudden my 2005 stops forward motion and I hear and feel a terrier grinding noise. Read some threads on mud and push Center Diff lock on dash and that seems to make it so I can drive to mechanics. When I arrive and disengage CDL truck seems fine. Mechanic tells me to take around block and it still seems fine. About 20 mins later problem returns and I was able to once again fix it with CDL button and limp to mechanics shop. Some real time help here would be great as mechanic who is awesome is booked a couple weeks out.
 
The terrible noise is your best clue where the issue is. I suggest you walk beside while someone else drives the vehicle going slow with cdl off (if possible) and listen front and rear for the noise. It’s possible it might be in the center area indicating the transfer case or transmission, but I feel that’s less likely.

If it’s the rear noise it’s in the diff, if it’s front it could be more than one thing, diff or cv joint in one axle. The front is the most likely and cv is the most likely of the front options.

The above is not a complete answer but a way to find more clues. You could do the same on a lift with all four wheels in the air.
 
What was weird is that after I engaged the CDL drove it and the disengaged the CDL it drove fine for probably 20 miles before it gave me grief again. If it was the drive flanges would it be temperamental or a permanent problem?
 
Axle may be moving in and out of hub flange. Just happen to have been in, once CDL turns off.

Very easy to check.

Either pop off grease cap. Or even easier. Grab outer CV tulip of FDS and see if you can pull out of Steering Knuckle from the back.
 
Just wanted to give everyone a follow up that it was indeed the drive flange c clips! Thanks again weird internet land for pointing me and my mechanic in the right direction!
 
Here's a new video to inspect snap ring gap or even if off in a field test. So easy!
If you can see movement of >0.20MM (1/2 the thickness of a fingernail) it's too much.
 

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