Transfer case rebuild

[Squall]

Originally Posted by Wooders

Squall, you don't say if the problem only occurs in 4wd or not, just in which gear, which would lead me to think it is not the t/case chain. (good for you since you don't want to be splitting the case in BFnowhere).
Check the transmission mount. Also mark each uni cap relative to the yokes and check that the cap isn't spinning relative to the yoke.

Thanks Wooders, I will try both of those ideas this morning. The clunking sout occurs in 2H but this thread was the best one I could find to describe the sound and my problem on search.

Thanks again for some great ideas.

[Wooders]

No Prob. Well definately not the t/case chain
If you get stuck give me a call & we'll see what we can brainstorm over the phone.
Cheers

[Gianni]

Hey. Picking up a new t/c this weekend with sye. Then I'll pull cover offline and inspect and get back to you. There is heaps of oil build up around the transfer case :s

[skwake]

I remember seeing a great video on youtube of a mechanic rebuilding one in 3 or 4 minutes on a bench. I will have a look...

[skwake]

Couldnt find it but there is one of a SYE install and another of a dissasembly. Both informative

[Squall]

I think I found my problem. Thank the heavens it was not the transfer case in the end. This UNI joint has seen better days.
That cap on the left has smashed to pieces just as I pulled into repco to get a 8mm socket I didn't have. The one on the right was just full of powder where the roller bearings should have been. Now down to two spare unis for the rest of the trip. 30 minutes to fix on the side of the road though and not something major like I was fearing.

[anthonygubbin]

Squall better buy a lottery ticket. It may only be a rumour but I have heard of major accidents occurring when a uni lets go and digs into the ground.

Regards A