Transfer case rattle/grind
I bought this TJ back in July. It's had a weird rattle/grind comming from under the driver seat since I bought it. I assumed it was the U-Joints and just pulled both drive shafts recently and all joints operate quietly and have no slack in them. I've been driing for a few days without the front driveshaft because I am convinced that it was the CV joint making all that racket. The noise is directly related to vehicle speed, not engine rpm. It's kind of like a chattering/slapping sound as you accelerate/decelerate/ maintain speed. Its best heard at 30mph and below. It happens in gear and out of gear, clutch in or clutch out.
Today after doing a search for "marbles" I got some pretty interesting info. Decided to try an experiment. With the JEEP PARKED, ENGINE OFF, I put it in 1st gear, and transfer case in 4lo. The front driveshaft is still off. I crawled under there and tried to spin the front output yoke on the transfer case. It's got about an 1/8th of a turn in it. That seems like an awful lot of slack in there. Should there be any play in this thing? Seems like it shouldnt be able to move at all. Any info would be great, I'm tired of hearing this grinding/rattling sound as I pull out of gear and slow down.
Green 1998 Sahara