OK, so I'm not having any luck searching around so I'll go ahead and ask. I noticed today that when I'm braking I get a very noticeable growl from the TC when I'm braking. It's the same noise you get if you put slight pressure up or down on the TC shifter while driving. Didn't used to have this noise.

I've had some noise in it periodically and rebuilt the thing in the spring to make sure nothing was going bad. That was about 4,000 miles ago. I changed the fluid about 1,000 miles later and noticed a lot of aluminum powder suspended in the fluid. I put on a Tom Woods SYE kit about 1,000 miles ago and changed the fluid then too.

I had a SLIGHT leak that I found a couple weeks ago where fluid was seeping past the drain plug but after tightening it a little more it went away. Thinking maybe I had lost more fluid that I thought I pulled the fill plug when I got home today and it was full. Thought I would drain it again and check for metal and sure enough it looked like pearl dust paint even though it was still a nice red/purplish color. I know it's aluminum too as there is a magnet in the T-case and when I run a magnet through the fluid it doesn't attract the particles. Being aluminum it would have to be coming from the cases somewhere unless the oil pump is digesting itself. Even then, I don't know how a chain with only 4,000 miles would start contacting the case.

I'm not sure what to think. The growling when braking is a new thing and it does it pretty much until I come to a stop. I haven't noticed it doing it lately but I've typically had the radio on (noticed it today even with the radio on.)

Anyone have any ideas?

 

Here's a pic of the fluid that came out with 1,000 miles on it (mixed a little.)

 

Does your 4WD still work? Mines had the same thing when the chain got stretched out and caused it to rub the case. The fluid was all pearly haha. Id probably crack open the case again and check to see if the chain is stretched out.

 

I was wondering about that so I looked a little closer before I refilled it. I can tell the chain isn't very stretched (if at all) from what I can see through the drain hole (way the chain is feeding off the sprocket), and the fact that I can still touch the inside of it by sticking my finger through the fill hole. Anyone ever had the chain move sideways? It's almost like something is being pushed forward by momentum when I'm stopping and making contact with something.

I guess the other question I'm looking to get answered is do you guys normally have a pearl dust looking fluid come out of the t-case when ever you change fluid? I've had it happen every time I've opened it up, but every time I've pulled the cases apart (three times now) I've not found any evidence of the chain making contact with the cases, or any other abnormal wear. Any thoughts on what's producing the powdered aluminum?

 

So I've been doing a little more investigating. I was questioning whether or not I was actually hearing the t-case or if the sound was coming up through the shifter. After disconnecting the shift rod coming from the t-case I found the noise to be MUCH quieter than when disconnected. So it appears that when the transmission moves under load/breaking it releases and binds the shift linkage in such a way that it transmits more vibration out to the tunnel and into the passenger compartment.

My theory is that the rubber grommets have gotten hard over time and/or the bushings are wearing out. I've ordered a shift linkage repair kit (one of these) to replace the rubber grommets and the bushings that look iffy. I'll update when I get the parts installed in case anyone else is experiencing something similar.

 

I ended up replacing the shift linkage bushing and it helped quite a bit. Found out once I got it off the little brass spherical bearing was seized up too. Didn't completely eliminate the noise like I was hoping it would (like when the shift rod is disconnected) but it did help a lot. One thing I should point out though is that the Crown linkage kit is crap. The bushings are all hard plastic. Go to the dealer and get the black bushings that are actually called grommets in the parts catalog and are actually a dense rubber from the dealer. I learned the hard way and had to buy two sets of parts.

 

Is it possible that you have too much movement because you really need new engine and trans mounts? just a thought

 

Fluid looks cool at least.

 

They don't seem to be dry rotted or particularly loose from working on the Jeep, but to be honest I'm not really sure of the proper way to check them.