Outer Limits 4x4 Board

If u guys had seen my last post regarding the Free Wheeling Hub,you guys will know about i have some noise problem when the hub is locked in 2WD mode.....but further investigation,the noise is from the Transfer-Case,not from the front axle......

Today i jack the front end up to check the front axle and free wheeling hub operation,i took the opportunities to service the free wheeling hub,clean it up and give it some refreshment with new Castrol LM grease,now it had alot smoother operation.....return to the topic,the front axle operation was perfectly fine.....i have turn the wheel by hand to hear where is the noise from,after a careful investigation....i found that the Transfer-Case had a clicking noise at every revolution of the wheel and when shifted into 4WD "4H,N or 4L" when u turn the probshaft clockwise the probshaft will move but it is a jerky move....it feel like the teeth of sprocket inside pass over the chain but when turn it counter-clockwise it is nice and tight....when driving around in 2H and the front hub locked i will get a series of ratcheting sound and some vibration on the gear lever there....it sound like those old train moving on the steel rail,hard to describe but it like a chuffing noise.....

So my question are:

1)should the front probshaft can be turned with the transfer lever set in 4WD mode with both rear wheel on the ground "this is a Part-Time 4WD"

2)Why would the transfer-case making noise when the front probshaft is turned by the front axle "FreeWheeling Hub Locked" and the noise disappear when using in 4WD

I really need help from those 4WD expert like you guys,i am totally lost now and worry that my 4WD system had anything wrong....i will mod and go off-road around Malaysia in 2 or 3 month later so the 4WD will take the full punishment from the bad terrain,if there is anything goes wrong during the trail i will be totally mess

Anyone

I wonder if the chain inside the Transfer-Case is stretched,can i adjust/replace it while the case is on the Paj?....cause it's a pain to get the whole box out

Pajero 4D56 wrote:Anyone

I wonder if the chain inside the Transfer-Case is stretched,can i adjust/replace it while the case is on the Paj?....cause it's a pain to get the whole box out

It has only been two hours ...

You got to be kidding "or maybe for a expert it can be done,but not for noobies like me " ......the whole thing including the gearbox got to come out as an assembly so it could be a big job....last time im sent it to a gearbox speciallist to replace the Manual box,it had taken a one and a half day to done it.....