I was having some problems with my t case , my truck was in gear but wouldnt go anywhere and it made a loud grinding noise with the clutch out, I tore it down and found the range fork was worn terribly, I replaced it and now the truck will drive normal till I let off the throttle and occasionally while still on the throttle it makes a grinding noise , it almost sounds like its hitting and grinding on something but its not a consistent grind, it will grind like 3 times then stop then do it once and then 5 times etc.. I dont know where to even start , Thanks in advance Taylor!

 

Did you put the plastic pads on the range fork? those make a difference in tightness.. remove your rear drive line and see if the output shaft on the tcase has movement. Almost sounds like the shaft is moving and its making your synchronizer sleeve slide into moving gears... If the shaft is loose, a snap ring is missing. Remove the tail housing and their should be a snap ring up against the bearing. Thats a real common one to break off.

 

The plastic clips are on the fork and there needs to be a snap ring against that bearing thats in the tail housing just to the rear of the speed sensor? Also when the t case is out of the truck the output shaft has about a half of turn worth of free play before it grabs and starts turing the whole t case and when it grabs it makes a clank noise

 

Yes, correct, there should be a snap ring there holding that shaft in place; from moving forward and rearward. What do you mean "before it grabs and starts turning the whole t case"? Are you referring to it turn the front drive line yoke? as 4x4 is engaged?

 

No you can spin the whole output shaft about a half of a turn before it grabs and turns the input shaft

 

hmmm, the output shaft goes all the way through to the tcase and connects to the low range gears.. maybe something is messed up in that locations..

 

Mine was doing the exact thing, I pulled my case and the shaft for the fork was broken among alot if other things, I ended up getting a 2wd 241dhd and using my 4wd shaft to make one good case, the reason my fork snapped was because the thickest of the 3 snap rings which is at the end of the sgaft to hold it tight,and keep the whole shaft from moving was broken, so, on my case,i just got done doing I put a new ring on and tack welded it all around, I will post a pic if I can. Just be sure not to mess up,the bearing in the case housing, as for the tailshaft housing the tacks dont get in the way or affect anything. My shifts have,no noise,anymore.