Transfer case rebuild

[Gianni]

Hi there. My transfer case tends to grind a little when set to 4H. I either need to rebuild it or source a new one. What are people's opinions.
Hard to rebuild (what will I need), and how much are parts?
how much can I pick a second hand one up for?

[MidnightMods]

Grind as in what way?

[Gianni]

Well ill drive along and it will randomly clunk. Feels like its popping out of gear but its the transfer case. I'm thinking a syncro as its fine in 2H

[Richo]

Clunk when driving in 4wd..... on bitumen you mean?
In 4 hi and 4 lo range?

Going up hills, or down, or on the flat?

[Gianni]

Originally Posted by Richo

Clunk when driving in 4wd..... on bitumen you mean?
In 4 hi and 4 lo range?

Going up hills, or down, or on the flat?

It's a clunk in 4H like its popping out of gear, but whilst driving in 4H there sometimes was a little crunch like when not in gear properly. I've only done it on the street. I think it was fairly flat vmaybe downhill slightly.

Doesn't do it in 2H, haven't tried 4L

[Richo]

As I said in your other thread, get under it and check the linkages.... either they have slop in them, or they arent adjusted correctly. The transfer lever you pull is bolted to the floorpan (trans tunnel) then is attached to to the TF case, and you get some wear and slop in the linkages in between. It may be that 4wd/lo range isnt engaging properly.

[Darius]

If I had just bought it, first thing I would do is drop ALL the fluids and a replace them with good new stuff.