Ok to start with, this was my girlfriends jeep and it is a 2002 overland with quadradrive.
Fall-ish of last year she said something to me about it making a weird noise (we all know how that is). After a few months of neglect, i drove it and tried to find the noise with no luck. Mainly because it was winter and i didnt want to be cold. So anyways, she kept driving this thing up until a week or so ago and never really said anything more about it. Well we bought her a new car and i was going to start driving the WJ again until i noticed how bad this noise had become. At first it sounded like tires rubbing something now it is loud growling and popping when going around a turn. (ONLY when turning i might add) So im sure you are all thinking the same thing i was, rear diff isnt unlocking. The fluid in it was getting old (20kish miles) so i figured maybe it was degraded and the friction modifier in it wasn't doing its job. Well tonight i changed it was royal purple and added some extra friction modifier and it didnt change a thing. So now im back to the drawing board. I fully expected chunks to fall out of the rear end when i took the cover off tonight and to my surprise it looked perfectly fine. No chunks, no excess metal in the magnet, the fluid even looked translucent still.
So.....I really dont know where to go next with fixing this. Im beginning to think its not the rear end now. (tcase maybe???) But i guess driving on it so long with it binding could have damaged the variloc somehow. I have no problem putting a new rear axle into this thing, or a tcase or whatever it needs, but i just dont want to throw parts at it. Half my problem is, its hard to simulate the vehicle turning with weight on it while trying to look for the problem. The rear end seemed twitchy and jerky when looking at it while turning before but that could also be feelback all the way from the tcase just as easy as it is the rear end. I thought about pulling the rear DS and driving it but im not sure if the rear tcase shaft will fall out or if bad things will happen.
So if anyone has any ideas please let me know. I really need to get this thing back on the road again. Thanks guys