I've had my 1995 Jeep Cherokee for a few years now and changed the T-case fluid a year ago due to a rattling noise. That didn't fix it but the rattle went away later so I thought nothing of it. Just recently the rattle started again and I couldn't pinpoint it. However, yesterday I tried to use 4WD going up a hill and a god awful grinding came from somewhere in the front end. I had someone else try so I could listen from outside the car and the back wheel would spin but the front would do nothing.

I'm thinking it may be the transfer case chain and that it stretched. Is this easy to tell by pulling the transfer case apart? If so, can the case be rebuilt or is it better to just buy a new one? Also, what would have caused something like this?

 

The rattle was more that likely one of the friction pads going out on one of the shift forks in your TC. Bet the grinding kinda has a pop/klunk to it too huh? Had the same type of noise with mine after the PO ran it dry for a while. The 231 (assuming thats what you have since you didnt specify) is an easy case to rebuild.Do a couple of searches and you will find plenty of info on how to rebuild it. Good luck!

 

or get another TC from the junk yard.

 

Ever try adjusting linkage yet search that first...

 

I'll probably wind up doing a rebuild on it. I was thinking of grabbing one from a junker/parts car but it'd be just my luck to throw the "new" one in and have the same problem with it.

I believe it is an NP231. I checked last time I crawled under it but I'll check again before getting parts.

As for linkage goes, would that cause it to only make the grinding noise when under load? If I put it in 4WD and just cruise down the road at 10-15mph, there's no noise except the rattle. It's when I try to climb a hill that it sounds like it's grinding gears/chain. I can't imagine a linkage would also contribute to the rattle just driving down the road in 2WD.

 

Sound a lil something like this?

 

Go ahead and completely rebuild the case that will definitely fix all issues...

 

That's exactly the sound when trying to use 4wd.

The road noise rattle in 2wd sounds like a can bouncing around though.

 

Yeah thats your chain slipping. Bet the can bouncing seems to get quiter at higher speeds, but is down right obnoxious while crusing through a parking lot huh?

The rattling is your shift fork bouncing off of your range selector. It has nylon pads that are supposed to keep it quiet, but they go to crap in a hurry when you run the case dry. Had the exact same problem with mine after the PO negelected to replace the rear output seal and ran it dry for a while. Do a couple of searches on here and youtube and you will find all the info. you need. The hardest part of the whole deal is actually removing the t-case.

 

In this case I think it will

 

Thanks for the help. I want to ensure that this is the issue before I order a rebuild kit so is there an easy way to look at the shift fork and tell? Or is it a leap of faith to just rebuild it?

 

Since your chain is slipping its going to have to be replaced. Just to clarify the shift fork rattling and the chain slipping are two diffrent issues, both of which are usually caused by lubrication issues. When you split the case to cange the chain the fork will have to come out too. If it's worn it will be easy to tell. IMHO I wouldnt order anything untill I pulled it apart and found out what all is damaged.

 

That's what I figured. Yeah I'm definitely going to wait to order any parts until I take it apart. Problem is that it's the primary vehicle.

 

So I decided to pick up some fluid to make sure it was topped off and somewhat okay to drive. Checked levels; low of course. Started putting some in, immediately came out the bottom. Discovered a hole the size of a silver dollar. Guess you could say I know now why it was running dry.

 

Eh, not that bad....Little JB Weld and you should be good to go! I'd estimate a loss of 4 quarts per.....second?