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Old 01-17-2017, 01:59 PM
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Exclamation Grinding Noise and 4HI Won't Disengage

A few days ago my new 04 TJ started making a grinding noise when I was going fast and his a bump or dip in the road. It sounded like I was hitting a rumble strip and it seemed like it was coming from the passengers side. It got progressively worse so I jacked it up and checked steering and suspension. No problems. I then jacked up the rear end only to see if the wheels made any weird noises or rubbed when they turned. I put it in 2Hi and slowly let my foot off of the brake and the jeep began to move forward. I double checked that it was in 2Hi and it still did it. I then let it down and checked the transfer case. It was almost bone dry and what little tranny fluid was in there was black when I drained it out. I filled it back up and took it for a quick test drive. The grinding noise stopped. A few miles later it started again, and its continually getting worse. Pretty sure something is wrong with the transfer case since 4HI won't disengage, it had barely any fluid, and it was grinding. Should I just pick up a transfer case from the junk yard or is there something else I should test out first?

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Old 01-17-2017, 06:57 PM   #2
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A few days ago my new 04 TJ started making a grinding noise when I was going fast and his a bump or dip in the road. It sounded like I was hitting a rumble strip and it seemed like it was coming from the passengers side. It got progressively worse so I jacked it up and checked steering and suspension. No problems. I then jacked up the rear end only to see if the wheels made any weird noises or rubbed when they turned. I put it in 2Hi and slowly let my foot off of the brake and the jeep began to move forward. I double checked that it was in 2Hi and it still did it. I then let it down and checked the transfer case. It was almost bone dry and what little tranny fluid was in there was black when I drained it out. I filled it back up and took it for a quick test drive. The grinding noise stopped. A few miles later it started again, and its continually getting worse. Pretty sure something is wrong with the transfer case since 4HI won't disengage, it had barely any fluid, and it was grinding. Should I just pick up a transfer case from the junk yard or is there something else I should test out first?
Depending on how long it was run without oil it could need a total rebuild or replacement. A rebuild would be better than a junkyard one but I'm not sure on the cost comparison. Try to find out where the oil went. If you have a cracked housing, just get the junkyard one, if it's leaking from the plug, some plumbers tape may fix the leak. Still need to get it assessed though. Only way to do it is to crack it open

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Old 01-17-2017, 09:22 PM
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Depending on how long it was run without oil it could need a total rebuild or replacement. A rebuild would be better than a junkyard one but I'm not sure on the cost comparison. Try to find out where the oil went. If you have a cracked housing, just get the junkyard one, if it's leaking from the plug, some plumbers tape may fix the leak. Still need to get it assessed though. Only way to do it is to crack it open
Junkyard one is only $60 so I'll probably just do that
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Old 01-18-2017, 05:55 AM   #4
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Junkyard one is only $60 so I'll probably just do that
Yeah that's hard to beat! Give it a shot. Your transmission is probably not the one making a noise but if the fluid is black you should do a change, drive a few thousand or even a year and do another. I believe you'll still have at least 1 qt of black old fluid in the torque converter even after you drain it. 2 drains should get most of the bad fluid
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Old 05-06-2017, 04:59 PM
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Ended up replacing transfer case with a rebuilt one and still had a grinding noise. Replaced the rear wheel bearings and they were bad but still not the problem. Then replaced u joints on rear drive shaft and fixed the problem
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