continuation of 4wd noise

i changed the fluid in the transfer case and the differentials. there were some small metal shavings in the transfer case, but other than that everything looks good. the noise is still there though. in 4wd it sounds like a rubbing/ growling sound. if i leave the hubs locked and drive in 2wd, i can hear the sound, but it is really faint. the 4wd works just fine, but i am worried about the noise. anybody have any ideas?

 

someone mentioned a dry front driveshaft in the first thread about this problem. how do i fix that?

 

The dana 20 is a gear driven transfer case so a little growling when in 4wd is normal. Not quite sure what the rubbing could be. Maybe a bad bearing in the case?

 

The slip joint will have a zerk fitting - apply the grease gun. If your u-joints don't have a zerk, you're best bet would be to remove them and replace with new ones that do.

 

Maybe you could unlock your front hubs, make sure the transfer case is in 2 wheel, lay on the ground and turn your front drive shaft by hand. You may have a dust cover on your front yoke bent and rubbing. Or you may be able to feel or hear a bad bearing in your transfer case. I'm sort of grasping for ideas to give you at this point but the more things you eliminate the closer you should be to finding your noise. If you are really careful, I'm cringing as I type, you could jack up your Jeep, set it on 4 GOOD jack stands, have a spotter set in the drivers seat and start it and put it in gear. While you lay on the ground and listen as everything is spinning you might get a better idea of where the noise is coming from. I don't recommend getting UNDER the Jeep, stay off to the side and watch for spinning rubber. Or if you know someone that could get it on a floor lift you could do the same thing. Second option much safer. And please don't sue me or anyone else on this site if you end up with tread marks on your scalp!

 

Adam, I sent you a E-mail but I forgot to ask about your U-joints. Have you checked them in your front drive shaft? Just trying to think of anything that can make noise. U-joints will get you because the noise tends to travel because of the hollow drive shaft. Just a thought. Good luck and let us know what you find.