XJ: T-case Noise after gear install

[Dirttorcher05]

Hey all I just installed 4.56 gears front and rear and when I got the axles back under my jeep I know have a very bad sounding chain or gear noise coming from my transfer case. The noise comes while in 2wd and 4wd and with the front drive shaft not spinning. Any Ideas?

[cweed]

Are you sure that the new pinion depth is correct. If your pinion depth is to deep you can add binding in the drive train. The problem is actually the rear diff and not the transfer case. The transfer case is just where you hear the end result. What was your back lash at when you closed up the diff?

Secondly, we just replaced the gears in an 87 XJ, went to 4:10's and it had a load popping coming from the transfer case. The chain was stretched as a result of trying to pull someone while driving in reverse. I would drain a little oil from the diff and look for metal flakes/ spec's as a spot check. May want to check that back lash again unless you are very comfortable with the gear setup.

[Lumpy Grits]

Who did the install?
Was a "pattern" ran AFTER eveything was torqued down and in place?
Open the diffs back up and flush with brake cleaner and run a pattern on both gear sets. You should be able to "see" any issues.
Check the oil level in your T/C. When was the oil last changed? What color is the oil now?
Respectfully,
LG

[Dirttorcher05]

Well the t-case fluid was changed quite some time ago and needs to be changed and thats going in tonight, as for the patterns they are both looking pretty good, I am starting to think i may have a shift or mode fork that is contacting a gear, the sound is a metallic rubbing almost like a worn chain. The sound started after the install of the front axle and long arm kit I took out my t-case drop brakets to weld in the arm mounts so I wonder if during this time somthing got moved around.

[Dirttorcher05]

Well I pulled the T-case apart tonight and the fluid looks good no metal shavings or flakes, the fluid is pretty thin though. Looking inside the case I see no marks no rubbing the chain is fine and has not hit anywhere. Im stumped, im thinking about pulling a t-case from pick-a-part and seeing if the noise is being caused by drive angles or somthing else, any ideas?

[Lumpy Grits]

Your T/case uses ATF correct?
Is there a chance the the front or rear D/S's are out of "phase"? That is the joints are not on the same position from one end to the other on each shaft.
Check your U-joint angle and lube'em(if you can,)check for ANY play in those joints.
Respectfully,
LG

[Elusive]

Keep in mind that when you change the gears, the driveshafts spin faster. The only thing your t-case will see is faster spinning yokes, so I'd look at worn CV's or U-joints in the driveshafts.

[Dirttorcher05]

Ya thats my next move i am going to check the drive shaft relation and probably just replace all u-joints hell auto zone has them for about 13 bucks a pop, thanks for the input guys.