KK transfercase failure

[BaldyTJ]

Giday. Today 4x4in nothing extreme but was rocky. I bumped into a rock and the dreaded cluck happened. Thinking is was a CV gorn wasn't overly concerned as it happens when you play .( not that I have had one let go before myself ) . But after jacking it up and unable to figure which one was gorn the noise came from the transfercase. Dropped a bit of oil out into a clean container and the dreaded cluck straight away dropped into the container. Put drainplug straight back in. Looked in container and besides a silver flecks through the oil a tooth was sitting in the bottom !!!!!!! Has anyone else had this problem ?

[KKnut]

I’ve never seen the topic come up in the KK section, I’m thinking you’ll find something over at KJ. I assume the transfer is the same, maybe even common to JK too? There’s a few members in those sections that know these vehicles better than their own children, so if the topic doesn’t exist it’s worth asking there.

[CibbyDoc]

Originally Posted by BaldyTJ

Giday. Today 4x4in nothing extreme but was rocky. I bumped into a rock and the dreaded cluck happened. Thinking is was a CV gorn wasn't overly concerned as it happens when you play .( not that I have had one let go before myself ) . But after jacking it up and unable to figure which one was gorn the noise came from the transfercase. Dropped a bit of oil out into a clean container and the dreaded cluck straight away dropped into the container. Put drainplug straight back in. Looked in container and besides a silver flecks through the oil a tooth was sitting in the bottom !!!!!!! Has anyone else had this problem ?

No mate but shit does happen. You sure it’s a tooth? If it is I guess you know what that means. I’ve had the CV closest to the TF case go and that clunks. But not teeth.


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[BaldyTJ]

Yep it's a tooth . Thanks to Jeeepartrecyclers got me a transfer case .
Model of tranfercase is MP3022 . I wondering if anyone knows if they are a week transfer case ?

[CibbyDoc]

No theres been lots of guys on here including myself that have given the transfer case a pretty hard time without it letting go. Just one of those things I guess.

[Wiz.au]

I have worked out I have a 'clunk', only in 4WD, right under the centre console/middle of car (so guessing from Transfer case). When I first heard it I thought I'd broken something. But now I can nearly 'make it happen', if I use 4Low & drive up a really steep hill, then use heavy engine braking going down the other side (clunk), or shift into reverse and drive backwards up a steep incline (clunk), then when I start going back up a hill forward, one single 'clunk' again when it's gets pretty steep.

My best guess is a 'not quite tight enough' propshaft/driveshaft flange between the transfer case and the front diff. It's just 'that type of noise'. A single 'clunk' when the flanges rotate/slip until the bolts stop movement, and then going the other way, the 'play' is taken up again with a 'clunk' when the flanges rotate back the other way, until the bolts stop it.

Only happens under quite heavy load, so 4Low, 1st gear only. Can't ever recall it in 4Auto. Doesn't happen all the time, only under heavy load, so it must be holding fairly tight, just not tight enough for real high torque.

But it feels/sounds more like it's coming from the gearbox. Guess if it was the flange on the transfer case output, that would make it feel 'gearboxy'?

Anyone that experienced transfer case trouble care to describe what happened / how it felt?

[BaldyTJ]

I have replacement Transfercase in . Pulled old one apart to see what failed. The gear for the output shaft for front diff was half stripped its teeth on both set of chain gears . Dam !!! I now have some shed wall art lol