1997 TJ with clunk/grind in 4wd

[stoggy97tj]

I am a new member to jeep word and I love my TJ, However..... the last snowfall was a sad day for me.

I was parked, in neutral and i was holding the clutch as i shifted into 4wd (high and low make same noise)
I drove a few feet as i let off the clutch and it made a clunk/grinding noise from the front end and it got quicker as i slowly sped up. The clunk/grind was similar to a binding? noise but its hard to describe but its definately not healthy.  It happens in 1st forward and if im backing up as well.

My problem is I am new to the jeep and its solid front axle.  The front driveshaft and its ujoints were all good but i could move the front drive shaft maybe 1/8th turn before it contacted the diff gears. And my tires are the same size front and back.  I was told the ujoints on the end of the axle can make this noise but im not too sure how to test them. And im really hoping its not the diff..... it sounds too far forward to be my transfer case.

If anybody has any experience or history with a similar sound please let me know, i want to use my jeep!


Thanks alot!
---
Mike

[BrokenAxle]

is it in 4wd only?  if it is in 1st and rev only then might be your transmission.  if it was the diff or t-case should be there all the time in 4wd.  probably not the diff or you'd probably hear something in 2wd aswell because the diff is always turning - even in 2wd.

[stoggy97tj]

Its only in in 4wd and im not sure if its in higher gears, while driving in 2wd everything is smooth and quiet until i turn sharp then it makes a "binding" noise?

But in 2wd normal driving works excellent until im turning sharp (like parking in a parking stall etc)
4wd clunk sounding noises come from what sounds like front end.....

[rainemaker]

I am thinking you have a 231 t-case, I had a dodge with some very same symptoms. here is what I went through finding the problem. I checked my rear end  and nothing, so I took it to a tranny shop and just got a mech to come for  a ride and this is what he did, he said drive slow and then he put  two fingers on the 4wd leaver and pulled back lightly and he felt and I heard the noise and finally the problem was found, it was the syncronizer  in the t-case which alows you shift from 2wd to 4wd. Just my 2bits because it souds so much like my old issue. Hope all goes well.

[stoggy97tj]

Any and all suggestions are appreciated due to my lack of jeep experience..... how hard was the fix if it was the synchro?

[rainemaker]

easy, just need some hand tools wrenches sockets and such, then I took off my drive shaft(4bolts) and I took the transfer case right out to work on it on a bench. the case is aluminum and not that heavy at all. if you want to do it yourself I would suggest a Hanes manual from cambodian tire and just take your time the whole procedure took me about 4hrs total labor and I did my rear tranny seal while I had the t-case off. I got everything apart went to the parts place(your choice) and got him to print out a parts breakdown for me, I took that back and circled the thing I needed and ordered it, you could look used to, that is totally up to you I just spent the coin. I am glad to help if you have any questions. let me know if you are going to tackle the problem and I will try to be near the comp for questioning.

Jordie

[stoggy97tj]

Right on, thank you for the info, I dont have access to my work hoist right now but in the next few weeks im definately gonna look further into it, And good idea on the hanes manual