LX450 Transfer-case Noise and CDL Light Flicker (1 Viewer)

[SP76FJ40]

Working through a build of my 1997 LX450 with 155k miles.

We are almost dialed in on all the items of the build.

Notably Dobinsons 3” long travel heavy springs and mrr shocks, 37” Toyo’s, axle rebuild plus 4.88 Revolution gears, Toms front and rear double Carson drive shafts, rebuilt transfer case and 3:1 low range Sumo gears.

Rig rides extremely nice, goes good and every thing seems good under load or coasting but having a particular issue with some noise from transfer case when minimal load is applied on it. Like getting up to speed on freeway and then letting off and barely depressing the gas. Does it at almost all mph range same same.

The rig does not have a center diff lock button, so run in high full time. The other item which assuming is related is the center diff lock light on dash comes on for a second or two randomly also.

I don’t know how to post a video but here are some pictures in series. You can faintly hear the gear noise/vibration in these moments and see the dash light flickers.

The axle lockers work great and low works fine. Seems to be in high and noice vibration noticeable at 40-75 ranges. Center diff light flashes erratically from rolling through top speed.

We went through a bunch of forums looking but stumped on this one and pulling out hair at this point. Spent too much money not to finish dialing in.

 

[voodu3]

Does the light come on when you put the transfer case in L? Sorry didn’t read.

 

[MrMacdugal]

You also mention the T case has been rebuilt, which means it has been opened and worked on, which means margin for error, which is more than likely the culprit... I would expect... Unfortunately...
Does the noise sound like something rotating, grinding&rotating or vibration?

These could help narrow down something?

 

[SP76FJ40]

You also mention the T case has been rebuilt, which means it has been opened and worked on, which means margin for error, which is more than likely the culprit... I would expect... Unfortunately...
Does the noise sound like something rotating, grinding&rotating or vibration?

These could help narrow down something?

We went through it twice just to make sure. Wondering what parts would also cause flickering center diff light on dash.

 

[SP76FJ40]

Does the light come on when you put the transfer case in L? Sorry didn’t read.

Yes, low works fine and so do the front rear lockers. Only in High is there Flickering and gear/vibration noise during light load.

 

[jonheld]

We went through it twice just to make sure. Wondering what parts would also cause flickering center diff light on dash.

If the CDL actuator motor was not in either the fully locked or fully unlocked position synced with the shift fork internal to the transfer case, it could cause grinding as well as an intermittent dash light.