Well this may not be the right area to post up but I figured I would give you guys a shot first, since you have all helped me so much get this ol pick up the road. So anyway here is the issue, figured I would take the truck out for a shakedown run before I head down to the meet and greet next month.. Everything is good to go so I figured I would double check my 4 wheel drive system. Pulled into a soft dirt lot, lock the hubs rolled for about 20 feet make sure that you're fully engaged and then put the transfer case into 4 wheel drive. Drove around for about 5-10 minutes making figure it circles and making sure everything is working properly. So in this lot there was enough room to get the truck up to speed in 4 wheel drive high, meaning under about 35 miles an hour, so I did. Oh boy the transfer case sounded like it was between two wheel drive high and 4 hi, like a grinding sound at higher speed. Going slow no noise at all, 4 low worked great at lower speeds and tell I got up to about 25, same type of noise that was heard in for high. So here are some pictures of my current tires on the truck I know if you have brand new tires on one axle and completely bald on the other axle you will have problems like I described, but here some pictures to let me know what you think. If it is a tire issue.. Meaning one axle is spinning slower or faster than the other causing the transfer case issues


Front... And yes I did do my allin. about 2 weeks ago, the only thing I was out was toe


Here are the rear tires, obviously wearing fine lol

 

Looks like you are due to rotate the tires. I don't know if that little bit of a difference would cause any noise though.

 

Also with hubs locked a case in 2wd I can drive freeway speeds and no issues.. same thing when when t case in 4 high and hubs un locked no issues, so it might be a tire issue but I don't have a tread depth gauge till Monday.. on a side note when I did do the t case service no metal came out and fluid was still red...

 

Do you have a CV joint in the front drive line? If you do, I have a $10 bill that says it's bad.

 

Good point, I didn't even check that. I'll have to check that in the morning

 

it's a u-joint, there are also bearings on the stub shafts you should check and don't forget about the middle u-joint

 

Remember, if you're in 4WD mode -- hubs locked, T-case in 4x4, you're going to be slipping the tires slightly. IIRC, our front/rear diff gear sets are .01 different in ratio, which means /something/ has to slip a little.
Even if not, any little differences between front or rear, not going perfectly streight, etc, will cause speed differences between front and rear... which in our fully-geared system means slipping tires.

Honestly, I wouldn't run it in 4wd unless you're on muddy/icy/slippery terrain; where the added traction is useful.
If things go between icy and dry -- main roads are clear, little roads and parking lots icy, for example -- keep the hubs locked in and switch between 2-high and 4-high when you need it. You can do this transition on-the-fly, BTW, though I would recommend letting up on the gas/putting in the clutch when you do so.

 

i will second the bad universal in the front driveshaft.

 

Give me a few hours and I'll post up a video, when I went through my front end I checked all bearing/ repack and joints. All were ok, however I did not check the joint at the case... since I don't have the carpet in I'll pull the tunnel cover and post a video.
Thank you guys for the help so far

 

How's the oil level in the transfer case? Has it ever been changed?

 

Every single fluid has been changed in the truck about 2 months ago when I got it, if it look clean I still change it anyway so I know when it was done. I'm uploading a video now to Photobucket should have it up in about a half hour or so I have it running in 4 wheel drive in my backyard. Definitely coming from the transfer case, it doesn't sound like it is engaging all the way but front and rear tires are spinning. Sounds as if it is in between gears

 

Photobucket is being dumb it won't show my video.. posting to YouTube

 

I'm going to pull the back half of the case now

 

I'll agree that something doesn't sound right there.
I think there are plastic things on the shift forks that can wear out so you might be onto something there.

 

Uploading pics and video...