Twin Stick Tcase Noise

[wilsonasantos10]

1975 CJ5 . I've got a twin stick Dana 20 Transfer Case mated to a T-15 3 speed.

There's a pretty noticeable "grinding" noise coming from the Transfer Case when the front is in 4 Lo. Grinding is the best word I can use to describe it. It also doesn't seem to want to engage in 4 Hi. I have a good video that's too big to upload for anyone who thinks they can help diagnose.

Thanks!

 

[mriplaybass]

First thing, make sure that you don't have one axle in Hi and the other in Lo. It sounds like your linkage is not adjusted properly. My guess is that you are only partially going into 4Lo. Disconnect the linkage for the front axle. Manually, fully engage the front axle shift rail into Lo range. Put your front shifter in the Lo position, then adjust the linkage to where it can be reattached to the shift rail. Of course this may alter your Hi range, but it's a simple matter of finding the happy spot where both Hi and Lo will work without grinding.

 

[wilsonasantos10]

I definitely don’t have the rear in hi and the front in lo. I follow your logic though and I’ll try that out. Thanks!

 

[wilsonasantos10]

There was definitely an issue with the shifter not allowing the tcase to shift into 4 lo properly. I fixed it and did a test run but the tcase is still grinding in 4 lo but again only on the front axle. I set both in 4 hi and the front felt like it was seized...id slowly release the clutch and it would roll forward but then there was a ton of resistance so I let off the clutch and it would roll backwards. Definitely something more here than the tcase not engaging.

 

[wilsonasantos10]

I put the front end on jackstands and set the jeep to 4 lo in the front. I could rotate the tires and/or driveshaft and watch it all spin with no noise at all. I had the rear in neutral because the front shaft won't rotate with the rear of the jeep still on the ground.

Still a noticeable rattling noise on the front when driving in 4 Lo.