Just bought a 99 4wd...omg what the hell

[lt1transam]

It makes it much easier but it is not required to remove the crossmember. You just have to get your angling right as you remove it. If an area on the t-case is overheating don't try to band-aid it. Investigate it.

No there won't be any band-aiding. Mag welding will be to replace any lost material do to rubbing and hopefully I can get away with doing the pump upgrade kit. What in there can make that popping sound? I did raise the rear up and put it in gear and the popping/crackling sound is for sure coming from the t-case.

 

[SunlitComet]

What t-case mode did you have selected when it was popping?

 

[lt1transam]

What t-case mode did you have selected when it was popping?

2wd

 

[SunlitComet]

Well that likely eliminates the chain being loose. I would guess the a bearing has taken a dump becuase of the oil issue from before. But have you grabbed the output yokes and tried shaking them real good?

 

[lt1transam]

No. Right now the case is kind of twisted up in there. I'm going to drop the cross member tomorrow and drop it out.

 

[lt1transam]

The plastic keeper for the output shafts bearing set came out. So all the sounds I was hearing were the ball bearings bouncing off of each other.

---------- Post added at 08:09 PM ---------- Previous post was at 06:52 PM ----------

Picture isn't the best but you can see all the ball bearings are hanging out together. Never good when the balls bump into each other . So a new bearing, seal to transmission, maybe pump "upgrade" shim. What other parts should I be getting? There doesnt appear to be any wear in the housing from rubbing.

 

[SunlitComet]

also get Auto-trac 2 fluid.

 

[lt1transam]

I called RiversideGear.com and their bearing measures exactly the same and from what he was saying has more balls in it. Ordered that and the trans adapter gasket. All of my seals look fine. Any suggestions before I put it all back together?

 

[SunlitComet]

Check the condition of the poppet plunger(name is probabaly incorrect) and spring that pushes against the the shifting sector. It can get really worn and create shifting dificulties. This is not the switch that is also against shifting sector from the top of t-case. It goes in from underneath.

 

[lt1transam]

Will do. Thanks again!