So i bought a 1992 XJ and the guy told me four wheel drive worked but made horrible noises. he thought that the axle shafts stripped out. well i went to replace them and found out that the shafts were in excellent shape but needed to replace a U joint. Problem solved right? wrong. it still works but still makes sounds. it sounds like its coming from the transfer case and it sounds like its slipping. it only does it when im trying to actually use the 4x4. as in trying to get out of a muddy situation. any ideas? vacuum control motor thingy?

 

Sounds like the Chain is slipping.You might need to replace it.

 

replacing a chain doesnt sound like fun. How hard is it to do?

 

The transfer case is a simpler animal then a transmission. The most difficult part is getting the darn thing out of the Jeep without hurting yourself.

 

Does sound like the chain. But if has been slipping for a while the gears may be damaged. Might be cheaper to just get a TC from a JY. Could be Just miss-adjusted linkage. Adjust the linkage to see if that helps. If not pull the TC, crack it open and take a look, if the gears aren't all chewed up rplace the chain.

 

so it wouldnt be the failure prone vacuum transfer case switch? or should i replace it too?

 

I think a TC is about a $100 item. Buy one, swap it out.

Razor is right...it'll not be fun getting it out. I don't even know where you'd start.