what are some symptoms of a t/c going bad?

[ThreeJs]

Do transfer cases exhibit any known symptoms if something is bad or worn inside the case.
To be specific. A BW4405
Chain noises? Rattles? I'm open to any experiences or information.

 

[drdoom]

Grinding and loss of high range are mostly the symptoms you will have in a 4405.

 

[rasouth]

When mine had trouble it made a whizzing noise when coasting around 40 mph. It was due to the fluid inside the TC drying out. When I opened it there was nothing but a gray crust all over, no fluid what so ever. Pretty easy to rebuild. Parts are not too expensive. Took me a couple hours to clean inside and replace parts.

 

[ThreeJs]

I have an uneasy feeling about the transfer case I installed a few months ago.
There is a noise the developed and it seems to be speed related.

A sort of thump/clacking sound on deceleration/ braking. May be more noticeable on a downhill grade.
Slows as speed drops. No noticeable sound when on jack stands.
Checked fluid and added about 1/2 +/- qt to top off.

I am going to remove a plastic cover over the top of the gas tank that seems to be loose and see if that helps first.

I still have my old T/C and am going to check with my trans shop for a diagnosis/rebuild cost of my old T/C.

 

[ThreeJs]

To be honest. I am contemplating rigging up the old transfer case in the garage like they did in this video.

I really don't need the 4 low gear and I think it would last for the rest of the vehicles intended use / life.

 

[RickOTR]

Mine started by making a clunking noise when coming to a stop, that progressed to a ratcheting or wheezing noise whenever I let off the gas. Ended up rebuilding it with the Omega front/rear case halves and a new range hub, updated fork, and electric shift motor. No problems after 4 years. Total cost was $450.