Transfer case grinding on acceleration?

Tiny
JENNIFER GRAY
  • MEMBER
  • 2003 DODGE RAM
  • 5.7L
  • V8
  • 4WD
  • AUTOMATIC
  • 180,000 MILES
I apologize in advance for the lengthy post... Recently (4 months ago) had transfer case replaced with a refurb as well as yolk on rear drive shaft and have had no issues with it. Had Ring and pinion gears, all seals and bearings in rear differential replaced 1 month ago everything was perfectly functioning for 2 weeks. I was planning a long trip (350 miles 1 way) and decided to take it in for a tune up and all fluids topped off etc. During my trip I started hearing a low howling when accelerating similar to what I heard when rear end started going. I immediately called the mechanic who told me first I was probably hearing the humming of the new big mud/snow tires I’d had put on when rear end was being done. When I explained it was not the tires as I could hear them separately, he advised the new parts in the rear end would “make some noise until broken in” and he would look everything over once I returned since I was nearly 150 miles into my trip. Shortly after I was coasting down the mountain and when I started losing momentum at the next incline and pressed the gas I got nothing(my manual 4wd shifter had jumped to N) I called mechanic again as he also replaced the transfer case and was told the linkage was not replaced when the case was and the bushings were probably worn likely causing it to loosen. By the time I reached my destination the howling was getting extremely loud when accelerating accompanied by a grinding that felt like it was directly under my foot. Mechanic told me again my rear and front ends were fine (but I should check the gear oil in both since he didn’t with the tune up/fluid check and the rear level would have dropped as the oil made its way down the axel) he was sure it had to be the linkage causing the issue and my T-Case was likely between gears. I instantly went into panic mode since I just replaced it 4 months prior after having the previous one blow apart on the highway 4.5 hours from home. The linkage bushings were basically dry rotted so to be safe I replaced the whole thing and bushings. Followed his instructions to put shifter in 4H before tightening down etc. I checked the T-Case fluid, and it was super low as in there was about 1/2 qt in there and it takes about 2. Again, something he was paid to check and didn’t not to mention he advised the refurb case had some fluid in it when purchased so he just left it at that and didn’t check the level after installing or add any. I didn’t see any metal in the fluid when I replaced it, however, I am still getting the grinding (in 2H haven’t checked 4H or 4L). Both front and rear differential levels are good (had to add about 1/2 qt to rear). And ideas? I’m wondering if maybe the linkage wasn’t set correctly as I just read something about putting the shifter and T-Case both in 2H before tightening down linkage (he only mentioned putting the shifter in 4H). I have a 350-mile trip back home in a couple days and do not want a repeat of blowing another T-Case halfway home so I appreciate any feedback.
Saturday, December 31st, 2022 AT 4:58 AM

11 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,643 POSTS
Any kind of grinding noise is not good and will not go away with time or a "break in" period. This tells me the transferase was maladjusted or not rebuilt correctly. The fact it was down on fluid is not good as well. I would take a sample of the fluid to see if there is metal in it, (small glitter like flakes) This will confirm the transmission case is having an issue. If you could upload a short video of the noise, I can tell for sure what's going on. You can upload it here with your response. Here is how to check the fluid condition by removing the fill plug, #13 on the diagram. Please upload an image of the fluid as well.
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Saturday, December 31st, 2022 AT 2:25 PM
Tiny
JENNIFER GRAY
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  • 8 POSTS
Transfer case fluid is good. No flakes. That is the first thing I looked for having gone through it with the Pinion gear in my rear differential recently. I was told the transfer case may be between gears (thinking it happened when T-Case shifter went to Neutral coasting down the mountain) when my in cab shifter is put in either 4H or 4L it doesn’t properly engage(the front wheels do not want to turn) however if I put the truck in reverse and roll back a bit before going into drive they will start rolling. I attempted to readjust the linkage to make sure both the in cab shifter and T-Case are in the same spot however my in cab shifter has 4 positions (back to front 4H, 2H, N and 4L) when attempting to move the shift lever on the T-Case by hand to match the in cab shifter the lever will only move between two positions not 4. Seems like maybe the front drive shaft is in a bind? I hope that makes sense.
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Saturday, December 31st, 2022 AT 7:07 PM
Tiny
JENNIFER GRAY
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The video doesn’t seem to capture the noise the way I hear it in the cab. To me it sounds fairly close to the sound my rear end made when my pinion gear was worn (a roaring that grows louder with acceleration) however when I start to slow down/brake I feel a sort of clank/bang like something hits right under when my foot sits on the floorboard.
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Saturday, December 31st, 2022 AT 7:20 PM
Tiny
KEN L
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Oh ya, that is something going bad, it is difficult to tell where it is coming from so it could be the differential or the transfer case. I would raise the truck in the rear and remove the drive shaft to be able to spin the pinion to see if you can tell if it is grinding. You can spin the transfer case yoke as well to see if you can feel anything grinding as well. You have a bearing going out somewhere. Thanks for the video, it helps me hear what's going on.
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Sunday, January 1st, 2023 AT 12:25 PM
Tiny
JENNIFER GRAY
  • MEMBER
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So, I dropped the front drive shaft which I thought was in a bind causing it to not engage into 4WD but apparently it is my T-Case not moving as it should. The shift lever is only going two positions even when the manual 4wd shifter in cab appears to be hitting them all. The attached video was taken while I had someone in the truck shifting through all 4 positions (mine is back to front 4H, 2H, N, 4L). That definitely does not look good.
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Sunday, January 1st, 2023 AT 6:52 PM
Tiny
JENNIFER GRAY
  • MEMBER
  • 8 POSTS
In the video my truck is running, transmission in N and brake pressed.
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Sunday, January 1st, 2023 AT 6:53 PM
Tiny
JENNIFER GRAY
  • MEMBER
  • 8 POSTS
So, at about 3:00am I remembered the “ “mechanic” mentioned finding a vacuum hose just hanging unattached to anything when he I had it in for a tune up the day before my trip. He couldn’t figure out where it went so, he capped it off. Could this have been my vent for the T-Case? And could that be causing the issue of it first kicking my T-Case into N and since seeming to be stuck between gears and making noise etc?
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Monday, January 2nd, 2023 AT 7:42 AM
Tiny
KEN L
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Thanks for the videos. I don't think the vacuum line will cause an issue, you are correct the transfer case does not seem like it is shifting, did you get a chance to spin the rear differential to rule that out? I am sorry this problem is keeping you up at night, please get some rest.
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Tuesday, January 3rd, 2023 AT 10:52 AM
Tiny
JENNIFER GRAY
  • MEMBER
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Rear differential is good. Just replaced ring and pinion gears about 5 weeks ago. Quick check on trans fluid on my work break earlier truck only idling about 10 minutes so not full operating temperatures but it was super bubbly and looks to be over full. I’m going to take it for a quick drive after work and check the transmission fluid again to be sure and if so, drain some to get it to a good level.
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Tuesday, January 3rd, 2023 AT 1:38 PM
Tiny
JENNIFER GRAY
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Well, I shouldn’t have spoken so soon, I’m now leaning towards the rear differential as well. After correctly checking the Transmission fluid no bubbles and levels looked perfect, so I decided to take a look at the rear drive shaft universal even though I just had it replaced. Universal is good so I figured while I was under, I’d check the gear oil level again and it is black as coal and sparkling which it definitely shouldn’t be a month after basically having it rebuilt. That was my first thought when I heard the howling starting up a couple weeks ago but the mechanic who rebuilt it keeps telling me it’s the T-Case or trans. To be fair I am still 350 miles from home so he hasn’t looked at it but he doesn’t even want to entertain the fact that it could be something wrong with the rear end that he just built. I’m no mechanic but even I know the gear oil in this pic that is barely a month old shouldn’t look like this. I’m assuming they didn’t balance the rear drive shaft maybe which is probably making the clunking I hear/feel when I let off the gas pedal quickly.
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Tuesday, January 3rd, 2023 AT 3:27 PM
Tiny
KEN L
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Yep, that is bad, something went wrong inside the differential. I would forward the image to your mechanic to let him know.
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Wednesday, January 4th, 2023 AT 7:54 PM

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