Most likely there all rusted in you can take the transfer case out by removing 6 bolts I be leave and leave the pan on its a lot harder. You could also put the new chain in by removing the front drive shaft yoke on the tcase and then all the bolts on side of the case that the rear drive shaft attaches. Just be aware these are not the best options
Okay, so I know it's been awhile since my last post, still havnt had time to get around to that t case chain, but what are the chances the sound could be coming from the pinion gear, more specifically if the crush sleeve and shims went bad in it. In a previous reply I said that I had rebuilt the rear diff, but being new to this wrenching thing, I didn't know about those. A friend told me this is a common problem and judging by how cheap and available the rebuild parts are I'm inclined to believe him. What are the chances these pesky 30 dollars worth of parts are responsible???
That's what my noise ended up being, jack the rear axle off the ground, remove drive shaft and spin a tire. I didn't have any in or out play in the pinion, just a steady growl. The sparkles in the diff fluid was a bonus!!
Just read through your thread, and I had the exact same problem. I narrowed it down to my 8.8, saddly the PO must have ran it dry but thats the chance ya take when you pick it yourself from a 97 Exploder at the local pick and pull. Anyhow, my issue was the carrier berrings. Under a load you could hear the constant friction being caused from bad berrings wearing out the race. So after further inspection I decided to buy the re-build kit and a set of Richmond gears because my pinion gear was on it's way out also. Long story short, that was my issue. Hope this helps
Nightcrew Member #093
DEER--- It's whats for supper!!
Sorry for revisiting an old thread but I have one more question. I still havnt gotten it fixed (had some issues with the family pop up and had to put the jeep on hold) my last question is are the pinion bearings the same on the inside and outside of the differential on the pinion gear
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