Hey Everyone,

Hoping someone could help me out. I have a 1998 Cherokee 4wd AW4 242.

Okay so I've had the jeep for about two weeks. The transmission fluid was really dirty so I was doing the drain and fill method. I drained and filled once. Drove around for a day. Drained and filled a second time and then headed out to go camping for the weekend.

We were about two hours out and while driving on the highway around 70mph a clunking that you could feel under your feel started happening. It would happen spontaneously 30sec through a few minutes apart. I pulled over and checked the transmission and engine oil and they all checked out. I pulled the fill plug on the transfer case and it was low so I filled it with about 1 1/2 qts. The problem still occurred.

I really had no options so we drove home. The whole time it would clunk every few minutes. One time we went about 15-20 min without any clunking at all. But when we finally got off our exit we started to accelerate after a stop light and there was really bad grinding that happened and my rpms jumped up for a few secs and it finally caught again.

It happens in 4wd and 2wd. When slowing down and speeding up (worse when speeding up). Turning and going straight.

I'm at a lost.

 

Sounds like at a minimum a bearing in the transfer case is toast. Could also be due for a complete rebuild or new TC due to a serious lack of lubrication.

 

I was worried of that. Since I purchased it 2 weeks ago I have been changing and flushing all fluids and transfer case and differentials was next on the list.

I thought it was the transfer chain slipping but that wouldn't happen unless it was in 4wd?

If I get under and move the rear drive shaft back and forth there is some play in the yoke? that goes into the transfer case. I don't know if that would indicate anything?

 

Well taking it to a jeep guy here in town because I don't have the time to diagnose it and I need it back on the road asap due to it being my dd. Will keep posted just in case someone finds this thread with same issue.

 

Check this out:

 

I wish it was that easy. and cheap haha Thanks for the suggestion though.

 

Ended up being the shifter fork in the transfer case. The gear that makes contact with it was binding due to premature wear. Probably due to lack of lubrication. New seals were put in but everything else checked out. Thanks guys. Thought Id let you know incase someone comes across this thread with same problem.