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Old 09-12-2010, 05:13 AM   #1
Join Date: Apr 2010
Location: Phx, AZ
Posts: 250
Transfer case POP - Clunk

Hello everyone, I need some help. I have 95 YJ with a 2.5L, Automatic, 4" lift, 130,000 miles.

I was wheelin last night and I started to hear a very loud Popping noise coming from my transfer case. It only happens when in 4 wheel drive and under heavy torque. Mainly going up steep hills with some off camber. To me, it sounds like a bearing chunking. I can actually FEEL the noise when it makes it. Almost like the tire is throwing a rock up against the tranmission, over and over again.
All the mounts seem to be fine. I don't "feel" it in the steering, I can feel it on the floor boards.

My buddy said he thinks its the chain slipping on the inside of the transfer case.

Any ideas?

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Old 08-28-2014, 03:10 PM   #2
dmaxthad's Avatar
Join Date: Mar 2014
Location: Yuma
Posts: 58
I have the same issue. I know you posted this YEARS ago but what did the problem end up being??

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Old 08-28-2014, 03:53 PM   #3
0III0forlife's Avatar
Join Date: Mar 2012
Location: Ridgway, Pa.
Posts: 3,296
It is most likely the chain slipping on the gears in the t-case. The chain stretches over time just like a motorcycle chain does, time for a rebuild.
'87 YJ, 4.2L built and bored, 8.5" of lift, 8.8 rear, AX15/NP 231, Tom Woods drive shafts, Flat fenders, 12,000LB winch, Custom bumpers, Rattle can paint job. Never completed...
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Old 08-28-2014, 06:24 PM   #4
Join Date: Apr 2010
Location: Phx, AZ
Posts: 250
Originally Posted by dmaxthad View Post
I have the same issue. I know you posted this YEARS ago but what did the problem end up being??
Never figured it out. When I put in the 5.3L I rebuilt the TC with sye. Never heard the noise again.
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transfer case noise

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