So, I have been trying to find a drivetrain noise for about a year anda half. It is a crunchy grinding noise only when torquing the drivetrain (low range climbing hills for instance). I have repeatedly checked and changed all the fluids (rear end, front end, t-case, transmissin) and have seen no metal. I had finally narrowed it down to the t-case and have tried many time to break it on the trail so I would know for sure. But the darn thing stayed together. Well, after a particularly dangerous recovery (lots of high swift-moving water - that story another time) the t-case developed a leak. I have a spare case and decided to change it out - kill two birds with one stone. Well, I again drain perfectly good fluid with no metal. I pulled the rear drive line then the front one. Shazzam! The double cardan joint looked like it had been put on a lathe and a bunch of metal cut away. I lked at the cross member and found it equally worn
. Further inspection found worn engine mounts. Sooo, when the engine torques up, the t-case tristed and the front driveline hit the cross member. I am having the cross member notched for clearance and am replacing the mounts. That should take care of the noise. As for the hole. It seems that the t-case skid plate has been skidded one too many times and had worn a hole right under the drain plug. I cleaned it up and will try my luck with JB Weld. If that doesn't work, I still have the other case. Here's a couple pics of the cross member:
View attachment crossmember1.bmp View attachment crossmember 2.bmp
. Further inspection found worn engine mounts. Sooo, when the engine torques up, the t-case tristed and the front driveline hit the cross member. I am having the cross member notched for clearance and am replacing the mounts. That should take care of the noise. As for the hole. It seems that the t-case skid plate has been skidded one too many times and had worn a hole right under the drain plug. I cleaned it up and will try my luck with JB Weld. If that doesn't work, I still have the other case. Here's a couple pics of the cross member:View attachment crossmember1.bmp View attachment crossmember 2.bmp
