ok! Bare with me please, I dont know a whole lot about cars. Im going to try to explain this the best I can. I really dont want to have to bring it to a shop if I dont need to. So!

I have 1996 cherokee with 83k miles.
So a few months ago it started making a weird sound. Sounded like a paint can rattling but only when I was moving. It wasnt loud but all of a sudden it got REALLY loud. I was told I need a new transfer case. Ok. So, took out the drive shaft and the noise mostly stopped. Now it does it whenever a hit a bump or punch it. but stops as soon as I stop. Any ideas on how to make it stop making noise until I can swap out the transfer case? Or is it even the transfer case making that sound at all? Its drivin me nuts. I also thought it might be a heatsheild. But idk.


Any thoughts appreciated!

 

The transfer cases on the XJ's are pretty sturdy beasts. It's rare to blow out a transfer case by itself - not to say it couldn't be a bad transfer case, just not what I'd expect.

How are the u-joints on the shaft you took out (front, I'm assuming)? Is there play in them if you twist them side to side? It wouldn't surprise me if the u-joints are original and have worn out after 20 years.
Have you been changing your transfer case fluid on a regular basis? It's a super easy and low cost thing you could try before spending a ton of money on a new transfer case.

 

Thanks! Im going to check that out tomorrow. Ive only had it for a few months so I havnt changed it, before me it was a city vehicle so im taking a safe bet on saying it was well maintained.

 

Big mistake....never assume. Previous owners may even say things like "I always performed all the maintenance on the vehicle when it was suppose to be done" especially when they are trying to sell it. For your safety and others on the road, take a day and do some "noggin pokin", pull the wheels, check out everything you can. You will be surprised at what you find. Merry Christmas and happy Jeepin'..

 

Check the transfer case shift linkage. Lots or moving parts and once the bushing were worn on my XJ, any engine movement due to torque made a popping sound inside. If you've got your front driveshaft out you've got great access to see what condition your linkage is in..

 

I think its the chain in your transfer case. They will stretch and start to touch the case on the inside. Not a huge deal to service.