BleedBlueOval,

MBBFORD & MiL1ion are experts on the transfer case stuff. If you are grinding I would check the fluid level first. I believe it uses 30w Non Detergent Motor oil....at least that is the concensus I have reached from talking with a lot of folks. That's what I am going to put back in mine. Grinding could be from U-joints, Transfer case spider gears on the planetary gear, rear or front axle housing, axle u-joints, or a variety of other driveline parts. You might have to give some details of when the grinding occurs, is it in Hi, Low, always... only when shifting, do you have locking differentials/limited slip diff's - (Check axle tag) etc. The Pro's here can help you diagnose the problem or at least get you some reasonable idea's of what it could be.
I would check fluid levels first. Then U-joints next.

There is a known problem with the shifter wearing out 2 bushings on top of the X-fer case where the shift handle attaches - you might have to replace these to tighten up your shifter for the X-fer case. You know these things wear out after 27 years.

Good luck. Hope it's not too $$$$$ to diagnose and fix. Probably something pretty simple. The X-fer cases are not too complicated...but those damn needle bearings... yeah not complicated but full of frustrations!

Take care.
Steven

 

The grinding only happens when in four wheel drive both low and high. And when i give it some gas. It acts like it grabs then slips and grinds. It used to just grind if the shift lever was not in the exact right spot but it got worse the other day when i was climbing a sand hill. I just replaced all the u joints less than 100 miles ago. Also, the rear differential was rebuilt less than 100 miles ago. It is a posi. I have Redline 85-140 gear oil in the rear diff. The transfer case oil is black so i need to change it out. I dont see a drain plug on it but i figure one of the bolts on the bottom will let it drain. My haynes repair manual calls for SAE 140W gear oil. I will eventually put synthentic in it also but after i figure out why its acting so wierd.

Thanks,
Syko

 

Did you ever figure it out?