Hello all, I am trying to figure out what is wrong with my transfer case.

I have an 89 limited auto with an AMC NP242. The jeep is lifted around 2 inches and has a T-Case drop. A couple of weeks ago I really started using the full time 4wd a lot more with all the snow we have been getting. I noticed it was making noise and not shifting well. I checked the fluid and found it to be lacking, like none in there lacking so my gearhead card was revoked as I did not check this when I got the vehicle.

When I opened up the TC the chain had definitely stretched and there was quite the gooey mess inside. I got a new borg warner HV028 chain and installed it. Needing to get my jeep back running I didn't have time to order parts so everything else just got cleaned up but not replaced. Nothing popped out as bad from the look and feel of the parts. I did notice the 4low shift fork pads were a little sorry but still attached for the most part. All the bearing looked and felt OK.

Now I have new ATF4 and a new chain and it shifts great and is completely quiet in 2WD. In 4Hi I get a grinding noise (like a worn brake pad) only when applying the brakes. I have not noticed it in just letting off the throttle like when I had my old stretched chain but the noise is disconcerting.

Does anyone have any ideas about what the issue could be? There is no way my chain has stretched in a few weeks right?

I can try to supply more information as needed to help in the diagnosis.

THANKS!

 

Are you sure you got the correct replacement chain, did it have the same number of links?

 

Yeah, it's the same one Novak adapters sell for the 242. It has the same number of links and the same width as the old one.

 

could my chain gears be messed up and be allowing the chain to have too much slack?

 

When you had it apart could you see where the old chain was rubbing the case? That fact it does it under a load (braking) almost sounds like a bad bearing.

 

yeah the old one wasn't rubbing anywhere that I could see (no obvious scuffs along the plane of the chain), It was pretty sloppy in there but not enough to ever skip teeth. I was just thinking that if my pump went bad the bearings would not be getting oil. Before they were caked in sludge that may have been acting like grease and keeping them rolling fine.