I posted this yesterday with the title "Transmission?", but thanks to a response on that thread I'm starting to think that it is the transfer case.
So I was driving home from work yesterday when my jeep just stops going.... didn't matter what gear it was in.... it would just stop, giving it gas it would stop go stop go with some horrible clunking noises coming from under me. Then it would go for bit and then stop go stop go again with the clunking. I've had a slow leak from the transmission for a while, I guess it's possible that there is very little fluid in there, I have been putting off filling it as I get more oil on myself than in the tranny. No problems putting it in gear and no clunking with the clutch in. Also, clutch was done last summer and timing chain was done a month and a half ago. The fuel pump is a couple of years old and I wouldn't expect any awful clunking with that failing, plus it idles just fine.
So the transfer case and transmission were indeed fillled with oil, so there goes that idea. I have been hearing a chain rattle from underneath, not the timing chain either, since that was just replaced. Could a loose/broken chain in the TC cause the car to feel like it's losing power and make horrible clunking noises, then go again for a bit and then repeat? What inside the transfer case could cause this? I'm not very familiar with the TC, but am hoping to rebuild whatever it is that needs to be fixed inside, assuming of course it is the transfer case. (all of this is in 2 wheel drive, haven't tried 4 wheel since this happened). ...funny, my fiance was just complaining about the money I throw at my trucks and I said, "don't worry, there's nothing wrong with the Jeep." Great. Thanks.
The noise your hearing could be your magnet loose in your transfer case. The magnet is there to catch loose metal shaving and such. Its number 35 in the pic. Open your tcase up and take a look. Its not really a bad thing to get into. Just make sure when you put it back together you get some RTV gasket seal to put around the edge.
If I was you I would take the transfer case out, open it up and check it out.
Check the gears if any teeth are missing, check the magnet inside for any metal particles or anything like that. Make sure the chain is tight also. The chain is what seems to be the problem to me. That it gets slack which causes it to stop then tightens back up when it starts going and that keeps happening.
If it is bad then fix it, if it is good then put it back in and try it again.
1997 TJ with some stuff done to it.
So I'm going to open it up and check it out. I've got a couple of questions about the chain... how loose it too loose? I tried feeling it through the fluid fill hole, I couldn't feel it on top but I could feel it on the bottom, I could move it but I don't know how much it too much. Also, is there any guide for the chain and gears as far as how many chain links should be between the gears on top and/or bottom?
That layout of the TC is going to be great for when I need to put this thing back together, thanks.
LAXnyj18 - I hope it is just the chain, doesn't seem to bad of a job, and roughly $80 for chain and a few other things, not too bad.
Check the neutral shift fork and nylon pads that are suppose to be on it. (they are numbers 7 and 3 in the above picture. I had the same problem in my Ram 2500 and they were gone and the shift fork was worn pretty bad. It would let the neutral gear float between engaged and not engaged while I was driving and would get worse the more I towed. I was pulling 13k lbs through the mountains of NC when it got really bad. I put a new fork, and pads on it over a year ago and haven't had a problem since.
89 YJ with a 5.2l V8, 5 Speed ax-15, RC aals giving me 1.5" of lift plus 1" lift shackles giving me a total of 2.5" of lift, 31x10.5x15 A/T tires, no carpet, rinolined tub, Family style roll bar.
That chain does not look that loose to me. Keep in mind that when you have the rear half of the case off it is going to make the chain loose because the shafts are allowed to move. The rear case half holds the 2 shafts straight. Turn the shaft and check all the teeth on the gears.