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I posted before about this but now that i was forced to use it today, i have new information.
My transfer case shifts into all gears just fine. with and without hubs locked.
In both 4L and 4H it goes into gear all the way just fine. around the 30mph mark, a light grinding occurs. The road stayed the same, accelerator stayed the same and the shifter was never touched, it would grind for a second or two then stop. There was no pattern and i could not get it to grind purposely. While it was grinding i put light pressure o the shifter in both directions and it didn't help. And its a very light grinding, not a stop the truck something is coming apart grinding
My 79 does that if its not in gear right. I know you say "correctly" but even when it feels like mine is right it's sometimes not I have to play with it a little to get it to stop making noise. I have more problems trying to find 2 hi more than anything.
X2 on NOT using 4H or 4L on a paved solid road for sure. Dirt, gravel and snow covered. 2wd to 4wd H when rolling is ok, but 2wd to 4L you should be dead stopped.
Have you checked the fluid level and condition? Stick a pinky in the top fil port and you sound just get the tip wet. lol
Also before you add it, get a good sample and see if it smells burnt, and it is 89/90 gear lube and not just motor oil?
Have you ever got it hot and did a drain and flush and see what is in the catch screen? Pieces of gear teeth, roller bearing parts and pieces? A froze bearing can cause havoc to the race.
A light occasional grind could be sticking roller bearing due to rust. When you hear and have the grind have you ever temp checked the xfrecase? Spray water to see if it will boil it?
i have tried 4L and 4H on gravel not dry pavement. i know not to do that. I was on ice when i had to use it the other day. when i rebuilt the truck, about a year ago, i just resealed the transfer case. the oil wasn't bad that came out of it and everything looked great on the inside. I did check the oil yesterday before posting and its clean and full. I haven't done the temp check but i can.
What still gets me is how light the grinding is and how it randomly does it for a second at a time. no pattern or specific time
Might be a bearing that is locking up on you? Have you done a drain/flush and filter of the drained oil insp for metal shavings? That is a tell tell sign of something wrong in there.
My silver 77 xfer case works great, shift great, and has no grinding sounds coming from it. But after a long road trip (1hr +) it will get hot enough to boil water sprayed on it....