I just got back from moab with the cherokee. As I was on the trail in 4wd, under heavy load I would get a popping/clunking noise. I understand there is an issue with transfer case chains stretching and slipping. I just installed a sye a year ago and I also replaced the chain 6 months ago. Has anyone see a chain slip that soon? Only seems to happen in 4wd. I was able to drive the jeep home with no issues. Any advice would be greatly appreciated.

 

Have you checked axle and DS u-joints?

 

I have yet to check axle. I checked DS u joints and all are good. I am going to pull the cover on the axle tonight I just thought I would get some more noise if I did axle damage

 

No need to pull cover to check axle joints, or to even change them.

 

^^ just remove the brakes, hub assembly and slide out the shaft. Id check the axle ujoints out first then work your way back to the tcase.

 

I misunderstood the original post I thought he was saying to check the axle ring and pinion. I checked the axle u joints and all were good. I pulled the transfer case apart and was able to pull the chain off with out taking anything apart. the sprockets looked fine and there wasn't any metal in bottom of the case. I'm guessing I stretched that chain.

 

My guess would be not to by that brand again.
Care to share so others don't get it?