T-case help?

[jeepjeep!]

I have searched for an answer everywhere, I have an 04 Wj 4.0 with the Selec-trac, I have recently noticed when I put it in full time 4 there is a chatter or constant clicking when I press the gas. The faster I go the faster and louder it gets. If I go like 5mph it seems to disappear. Sometimes it will do it in reverse. When I put it back in 2wd it goes away. Also sometimes it takes a minuted to switch back into 2wd. I'm thinking maybe chain? If its even coming from the case. It used to hum a little in 4wd but just recently started chattering. 135k on jeep and tcase front and rear fluids replaced. Got up under it and driveshafts look fine and no play, i had my alignment man look at it the other day while rotating tires, i didn't mention the noise but he said things looked fine as far as alignment and nothing was worn in front end. Any ideas????

 

[Jester32]

Check your front driveshaft closely. Crawl under and check for play. Make sure tire sizes are the same and close in wear.

 

[Jester32]

There may be no play but could have a seized joint

 

[BaconYJ]

Maybe the chain within the TC has stretched?

 

[jeepjeep!]

Tire sizes are same, one on the front is brand new?? Others not so new. Maybe that's it? Seems to me if the chain was stretched I would have noticed before now. I haven't used 4wd alot since the summer but it didn't do it then and I used it alot.

 

[Bounty__Hunter]

My guess is a bad axle joint up front, or the t-case is going out. That's a relatively reliable t-case if properly maintained. How does the transfer case fluid look?

 

[jeepjeep!]

Good and pink, I changed it in the spring, maybe 10k on the fluid now

 

[jeepjeep!]

I can't tell if its in front or middle, hard to pinpoint while in drivers seat

 

[jeepjeep!]

How much is the front driveshaft supposed to turn by hand?

 

[Bounty__Hunter]

It should have a little play, maybe 1/4" turn when in park. Which type of front axle joint do you have, ujoint or CV joint? What's the condition?

 

[jeepjeep!]

Its u joint up front, it seems to be ok. No play or movement up and down or side to side, 4 WD still works good as its doing this also