Driveline Noise - Please Help

The strange part about it is that in 4hi and 4lo at any speed the case performs nice with no vibrations. One thing I noticed while I was driving it front wheel drive is how nice and smooth the truck was at 70mph. But im still gonna check the gears and see what I got just not lookin forward to it. Would yall happen to have a used set of gears for sale in the chance I have the wrong ones?

I used this guide to rebuild mine.
pirate4x4.com - extreme four wheel drive
 
I know you have already changed the rear differential oil but while you had the cover off did you physically check that either the ring gear or pinion wasn't missing a tooth? I've have witnessed many times a chatter coming from the transfer case that was being transmitted thru the driveshaft from a bad ring or pinion gear. Just thought I would throw this out there since you have yet to come to a conclusion.
 
79ihfanatic said:
the strange part about it is that in 4hi and 4lo at any speed the case performs nice with no vibrations. One thing I noticed while I was driving it front wheel drive is how nice and smooth the truck was at 70mph. But im still gonna check the gears and see what I got just not lookin forward to it. Would yall happen to have a used set of gears for sale in the chance I have the wrong ones?

I used this guide to rebuild mine.
pirate4x4.com - extreme four wheel drive
Click to expand...

I have n=3 spicer 18-5-16 intermediate gears here at my location if Jeff has none at hq! One of 'em I'll grade a 5 (some water etching on the internal bearing surface), one of 'em is a 7 (very slight water etching in the internal bore), and one is a 9 on a scale of 1>10. The 7 and 9 I'd put in my own stuff for my own use. The 5 I'd use in a trail rig but will probably have a whine to it even with new roller bearings installed.

I have no spicer 18-8-56 bull gears for a 727 app left, I do have some for other apps though (oddball Jeep). 727 gears are real spendy, the last one I had to purchase came from a used gear wholesaler in new jersey and I had to pay $125 for it, it was indistinguishable from new though. I believe Jeff does have a few of those at the Loomis location.
 
There was 2 large chips in the pinion gear one tooth about halfway gone but I found no metal when I cleaned the housing out so idk if those are new or have been there since before the noise started. Can a pinion gear cause that loud of a noise through the t-case and not at the rear diff? I am mulling over just sayin screw it and rebuilding the entire rear diff to see if that fixes it since it needs to be done anyways. The tag reads 45-11 / 4.09 so im assuming I need 4.09 gears. Manufacture date on the front and rear axle is 1976
 
So if I read that right the bull gear on mine has to be the correct one bc its the only one? But it is a possibility that the intermediate gear is the wrong one. Well how much do you want for the gear that you have thats in the best shape since I drive the truck every day I would rather go with that or a new one. I priced the new ones and im lookin at around 150 shipped. I will post my gear numbers this weekend.

Thanks again for the help
 
79ihfanatic said:
there was 2 large chips in the pinion gear one tooth about halfway gone but I found no metal when I cleaned the housing out so idk if those are new or have been there since before the noise started. Can a pinion gear cause that loud of a noise through the t-case and not at the rear diff? I am mulling over just sayin screw it and rebuilding the entire rear diff to see if that fixes it since it needs to be done anyways. The tag reads 45-11 / 4.09 so im assuming I need 4.09 gears. Manufacture date on the front and rear axle is 1976
Click to expand...

Yes a bad ring and pinion will cause a noise to transfer to the transfer case via the driveline just like what I previously stated. From all the pictures you posted I don't see anything wrong with your transfer case. We have ring/pinion sets in stock.
 
Ok so I pulled the d20 today and checked the numbers on the bull gear and the intermediate gear and they match up to the ones you posted I should have.
Bull gear: 18-8-56
intermediate gear: 18-5-16
 
So a mismatched bull gear/intermediate gear is not the cause of your issue. One more area to rule out.
 
Yeah so looks like ill be pickin up all the stuff to rebuild the rear diff. The tag on the fron and rear diff says 45-11 / 4.09 just to make sure that means I need 4.09 gears right? It also says the same on the ring gear
 
79ihfanatic said:
yeah so looks like ill be pickin up all the stuff to rebuild the rear diff. The tag on the fron and rear diff says 45-11 / 4.09 just to make sure that means I need 4.09 gears right? It also says the same on the ring gear
Click to expand...

You are correct!
 
Ok so the rear diff rebuild is happening this weekend. Ill post after everything id finished up. Hopefully this does the trick
 
Well did the gears change and rear diff rebuild and all strange noises have stopped. Only problem is the spider gears I ordered dont fit my trac loc carrier so I left the originals with chips in them for now. Anyone now where I can fint a set of trac loc spider gears? Or would I be better off putting in a lunchbox loxker like a powetrax?
 
Well ive found a few different lunchbox style lockers that fit the trac loc carrier like the lock right and the spartan from Yukon. But I drive the truck every day so im not so sure about a locker. I wheel too but im on the road alot more. Heres a pic of the carrier I have
 

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Your ring and pinion ,if it has minimal chips will last a long time, you have the same carrier that I do im my Scout 2 with 409s. Mine came from a Jeep j10. Just had to make sure the pattern matched and the lash was right.
As far as lockers, if you get a ratcheting locker you can still drive it normaly as you do now, the clutch packs in that carrier allow the slip with no noise or feel. The ratchet locker May pop or make a little noise but thats what its supposed to do. It will be ok on the street. Mine has a Yukon mini spool in the rear and I drive it on the street . Makes it a little hard to park at wally world sometimes but it aint nuttin you wont get used too.
Its 6 to 1 half a dozen to another, I still cant figure out why your new ring wont work. I swapped the open 409 carrier from front too rear on mine, and left the ring gears in theyre proper place. The reason I swapped was to spool the rear, and put the limited in the front, if I could luck up on an open 4 series carrier I'd spool the front too. Aint nothing like a 4 all the time.
All this probly didnt help but it mite give you some ideas or confuse the shit outta ya.
 
Actually my ring and pinion change worked just fine and the noise I have been having trouble with all this time is gone. Its the spider gears and side gears I ordered dont work for a trac loc. They dont have the guides for the clutch packs to set into place one. I guess they are for an open carrier and not a trac loc. I found a set for 250 for the side gears spiders and clutches but thats how much a lunchbox locker would go for.
 
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