[Help] Transfercase issues.

[killernoises]

Ax15/NP231. In first gear 2H. Chain was about to snap, i pulled it apart replaced bearings and chain. Drove it a few miles and it started making a grind noise but stopped only when i was accelerating. Pushing the clutch in didn't help. Only time it didn't make that horrible noise is when i was at a complete stop or accelerating. A few times it "slipped" while accelerating and i had to slow way down or stop to be able to drive again. Barely made it home chain felt like it was skipping and hoping. Went to investigate to find this. It spins that way but not the other.
Any ideas? Already know I'll have to pull it out again but how @#$%ed is it? If it's too bad i might get another one and swap chain or something..

 

Video:

https://m.facebook.com/groups/1402616813111625/permalink/4805851456121460/

[Pete M]

that's a new one by me.   I imagine opening it up will make things obvious. 

[MiNi Beast]

sounds like sun gears binding. id just pick up a good used one and fresh fluid and run it. i try to avoid shifting on the fly. not really ever needed. 

[ghetdjc320]

Sounds like your missing the snap ring on the main shaft that keeps the main shaft pulled back. It goes on in the speedo housing before the tail cone gets reinstalled. That missing snap ring causes just what you mentioned (can’t see the pic through)

[killernoises]

Just now, ghetdjc320 said:

Sounds like your missing the snap ring on the main shaft that keeps the main shaft pulled back. It goes on in the speedo housing before the tail cone gets reinstalled. That missing snap ring causes just what you mentioned (can’t see the pic through)

I also thought that's what the problem was but when i pulled the cone off the ring is still in place. When i was putting the driveline back on is when i noticed it spun in gear by hand and makes a gross noise. Lol

[ghetdjc320]

Hmm, are the shift fork pins located correctly in the selector switch thing? Also see is the shift collar was accidentally flipped over. Unless you have metal shavings in your case it’s probably fine but just has some parts missing or misaligned perhaps. 

[killernoises]

The way you install the shift selector you can't really mess it up i don't think. I installed it where it should be. By shift collar you mean that syncro hub? I never took the main shaft apart. I only took pieces out to put bearings in the case and then i put everything back together with a new chain. Sounded prefect one second and then the next second or sounded like two coffee grinders @#$%ing in a dumpster fire. The way it sounded and the fact that i had to drive it home from work like that (5 miles) I'd say there's shavings lol i was impressed it didn't grenade. 

[OldSch88L]

More info about your truck would help; do you have a CAD Dana 30 up front or not? If you have a CAD, then the chain shouldn't really spin that much in 2Hi since it's not engaged in the case, and the front left wheel will spin the spider gears in the carrier first, and maybe spin the driveshaft and chain just a little in some cases. If you have a non-CAD, I'd first try to remove the front driveshaft to see if it changes anything and to see if it's chain-related. If not chain related, the only other noise sources that comes to mind would be worn/missing nylon bushings on the t-case shift forks, making them rub metal on metal, or not engaging properly, or like Mini Beast said, maybe the input shaft planetary. I once put the wrong input shaft/planetary gear cut combo in my transfer case, and it made a hell of a racket! Otherwise, I'm out of ideas for now.

[killernoises]

Its an 89 with an ax15/231J swap. Mj D20 rear and mj cad D30 front. It used to be 2wd but I've converted it. Haven't made a front driveline yet so there's never been one in it, and the vac system never got hooked up for the axle either. I don't *think* the noise is the chain, i think it's teeth touching somewhere and binding on something but i don't know. The shift fork plastic pieces i changed for new ones when i put new bearings and chain in it. The planetary is the factory one that came in that case. I put it back in the way it was taken out.