Dana 18 Transfer Growling In 4l Or 4h

71 cj5. V6 dana 18 rebuilt using novac
Kit. Loud growling in 4l or 4h in 2wd is fine. Pulled inspection cover intermediate gear has
.045-.050 end play? Removed gear and all looks ok??

 

noise only in 4WD . front output bearing . or bushing in main shaft for front output shaft

 

That seems like a lot of end play, is this the standard roller bearings or a tapered intermediate shaft bearing conversion?

If you have locking hubs does it go away when they are unlocked? Are you able to remove the front driveshaft and see if the noise is still there with the transfercase in 4wd?

 

My first guess: missing the thrust washer on the front of the intermediate shaft, assuming this is still the stock layout. But that doesn't really explain the growl only in 4x4 mode as the intermediate gear will be loaded in both modes. Definitely check the intermediate shaft "boss" on the front side of the case to make sure that is not torn up.

 

Well good and bad news. Found pinion nut backed off 1.5 rounds causing major gear noise. Cleaned and locktite nut gears feel ok
Novac says case must be worn. Intermediate gear and thrust washers measured ok.
They suggest another case because of excessive wear?
State should be tight no end play especially not .045-.050
Thrust washers there and 0.125

 

I'ld try a18ga Shim or tapered intermediate bearings. A shim would need to have an ear to keep it from spinning against the case.

 

The AA tapered bearing shaft would solve that as you basically index off the rear side of the case with those. That said, by the time you get the intermediate gear machined and the kit, another case is a way cheaper option. I'm not sure I would be comfortable trying to shim that. The shim would need to go between the thrust washer and the case and still keep the thrust washer from turning.

 

Well now plan b or c... I mismeasured intermediate gear width. Mine is around 2.750 pulled another gear from spare transfer and it is 2.775. Gear looks like crap with teeth damaged. So now will go for bearing and use my gear.
Case looks good. Still trying avoid case removal. Don't trust Crown gears.even though that what novac uses.