transfer case problem

Hi everyone I've got a problem I'd like some advice on.

Four days ago I bought a '92 Chevy 3/4ton 4x4 (6.5 turbo diesel,
4L80e Trans, 241c transfer case). The day after I drove it home it
began making an intermittent clunking noise somewhere in the
driveline, usually during acceleration.

Yesterday on the way to work it made the clunk noise then *BAM* the
transfer case popped into neutral but the shift lever was still in 2wd
and making a grinding noise (like when shifting between 4 & 2WD and
the gears don't mesh). I stopped, shifted into neutral on the
transmission, then shifted the transfer case into neutral and then
back to 2wd. I shifted back into Drive and everything seemed normal
until I pegged the accelerator then *BAM* into neutral again (the
t-case lever still indicated 2WD).

The only way I was able to drive without the t-case popping into
neutral was in 4-Low...fortunately this took place on a dirt road 2
miles from my home.

Anyone have an idea what's going wrong? Thanks in advance.

Greg

Sounds like your range sleeve is not engaging with the hi speed teeth
on the input shaft gear. Could be a few things, but try to see if your
shift lever is moving the lever on the T/C all the way. Have somebody
move the shift lever from N to 2HI. Watch the linkage and see if it is
sloppy. After the shift lever is moved to 2HI see if you can move the
lever on the T/C further. You might have to wiggle the driveshaft some
to get the range sleeve teeth to align with the input gear teeth. If
the lever on T/C moves further then drive to see if in 2HI. If is then
repair the linkage. If not then the shift fork pads are wore out or
the range sleeve and input gear teeth are worn. Time for overhaul of
T/C then.


[email protected] (Krissi) wrote in message news:<[email protected]>...
> Hi everyone I've got a problem I'd like some advice on.
>
> Four days ago I bought a '92 Chevy 3/4ton 4x4 (6.5 turbo diesel,
> 4L80e Trans, 241c transfer case). The day after I drove it home it
> began making an intermittent clunking noise somewhere in the
> driveline, usually during acceleration.
>
> Yesterday on the way to work it made the clunk noise then *BAM* the
> transfer case popped into neutral but the shift lever was still in 2wd
> and making a grinding noise (like when shifting between 4 & 2WD and
> the gears don't mesh). I stopped, shifted into neutral on the
> transmission, then shifted the transfer case into neutral and then
> back to 2wd. I shifted back into Drive and everything seemed normal
> until I pegged the accelerator then *BAM* into neutral again (the
> t-case lever still indicated 2WD).
>
> The only way I was able to drive without the t-case popping into
> neutral was in 4-Low...fortunately this took place on a dirt road 2
> miles from my home.
>
> Anyone have an idea what's going wrong? Thanks in advance.
>
> Greg