Alright guys I have had an ongoing problem that I have not yet been able to solve. It all started when my first rear axle went out (D35), spider gears destroyed themselves. I went to the junkyard and bought a Chrysler 8.25 which worked out well for me for about 2 months. I was cruising on the interstate about 80 mph when I let off the gas and had this really loud rolling grinding sound (only on deceleration), clunking on depression when I hit the brake and when I hit the gas. It only did it at higher speeds but now it does it at any speed above 30 mph. I took the rear drive-shaft out and the noise was gone, took the front drive-shaft out (with the rear in obviously) and the noise was there. I have a spare driveshaft that I tried and it also made the noise with that driveshaft. I put the truck in 4WD and the noise is gone. So after a lot of research and asking around and I decided that it was the pinion bearing in my "new to me" high mile axle. I went and found a great deal at a junkyard on a low mile 29 spline Chrysler 8.25, yesterday I put it in and went for a drive, the same exact noise was still there. I did some more reading and people were dead set on the fact that my pinion angle was off. I only have about a 2 inch lift so I bought 2 degree axle shims and tried those. Still no luck, I am thinking that it is now my transfer case, thoughts?

Thank you guys for all your help and whoever can help figure out my problem gets a case of their favorite beer!! Haha

 

I'm not an expert by any means but my guess would be tcase output bearings or something in the tcase output shaft area

 

That's what I was thinking now too. The shaft does not move when I try to get any movement out of it though..?

 

I think there should be a tiny amount of play but again, I'm not a pro in this area

 

I suppose it could also be my chain that is stretched out in my T-case

 

Did you drop your transfer case after the 2" lift? Because mine did EXACTLY as you are describing after my 2" lift. I got 1inch transfer case spacers and it went completely back to normal...

 

Also, I used permatex anti seize and slathered the s*** out of the slip yoke. I know that helped too because I did that before the tcase drop and it helped slightly so a combo of both should help IMO

 

I will have to try that. The weird thing is that the lift has been in there since I bought it and it didn't do it with the first rear end. that's what stumps me

 

Well swapping from a D35 to the 8.25 could have created different angles and put extra stress on the ujoints. I say give the 1" TC drop a shot its cheap and takes about 30-60min depending how rusty the bolts are. Truck would groan and you can feel a grinding sensation when releasing the gas at speed. Went away 100% full year now after the tc drop. Oh and I have the 8.25 setup as well!

 

Sounds exactly like my t-case problem. Thought it might be the rear diff, but after popping the cover, the ARB locker was solid. Checked the t-case fluid level...bone dry. Uh-oh. Dropped it and sure enough the gears were toast. The plastic guides had melted and one of the gears had grinded to almost nothing. Replaced the damaged items and it's fine now. Got some advice from tranny & t-case guys to use 5w30 in the t-case instead of ATF. No negative issues to report.




Pic: These two should be exactly the same.

 

Did you use the same driveshaft with the 35 and 8.25? They're two different lengths the 8.25 has a shorter driveshaft then the 35. Could be too long and binding somehow.

 

I bought the shorter driveshaft, but to my dismay the original DS still has the right amount of engagment on the output shaft. But I did try using the shorter DS and had the same outcome. Looks like I am going to try the TC drop. Ill let you know what happens.

 

As far as the TC fluid, that is all good, checked that today. Even though this jeep is a leaker. Just add the fluids and keep things topped off!

 

I like Sam Adams... Just sayin'

 

I honestly hope your idea helps me. My life has been a struggle these past few months because of this jeep haha