Noisy D20 in 4Hi.

After my rebuild, I've got a noisy transfer case I think.

I've done a "mini" rebuild on my Dana20 and T14.Bearings, oil seals and syncro only.
Here is what I could find out to date.
In 2wd it seems to be fine in all gears.
In 4wd/hi with the hubs unlocked, it seems to be fine in 1st, a little noisy in 2nd, and a lot of noise in 3rd.
In 4wd/hi with the hubs locked the same noise as with the hubs unlocked.(No difference)

I haven't tried it in low yet, and it seems to be under "coasting" conditions where it is most noticable.

Can it be preload on the front output shaft bearing?I didn,t measure it when I reasembled the D20, but it doesn't seem to have any noticable play. I have used RTV sealant on the rear bearing cap shims of the front output shaft, so that might have something to do with it.
Is the intermediate gear turning in 2wd, or only in 4wd?

Any thoughts welcome and appreciated!
Okkie

 

Drive it with transfer case in 2 hi and hubs locked in. If noise is still there check front driveline, slip yoke, u-joints, etc. If not there then probably a transfer case noise. The intermediate gear is driven in 2 wd but acts like an idler.

 

Thanks nickmill.
I will check that.