Hello, been having a clicking / grinding noise when I put my jeep into 4X4. Going to be taking it apart soon to see if its the drive chain that is stretched, and inspect all the sprockets for any broken teeth / metal shavings in oil.

I've never tore into a tcase, so this will be my first time. Is there anything else I should be looking at while I have it apart?

Also, what type of oil is everyone using to refill, and what gasket sealant? I've seen a few different suggestions on google.

It is a 2001 XJ
231J T-case

Thank You.

 

Can you localize the clicking grinding noise more specifically. Typically when a chain becomes stretched its not such a subtle failure, the chain skipping teeth isn't a light hearted noise. It's rather jerky.

especially if your mostly stock I would inspect front axle components first. U Joints on the front axle shafts for example.

Also inspect your tcase linkage adjustment. Sloppy or worn out isolators with the factory shift rods can hang up the actual positions of the shift points not getting the full engagement. Can also verify this by disconnecting the shift linkage and shifting the tcase manually into each postion.

I'd fill your tcase with the same fluid you run in your Transmission which should be a Dex/Merc. Grey stuff silicon for the reseal job if you do tear it apart and No you do not need sealant between the Transmission and tcase mounting surface

 

Have you ever checked the fluid level in that transfer case?

 

Also check your front CV joint. If they wear out they can make all kinds of noise. And invest in a quality set of snap ring pliers