1996 5.0 AWD Transfer Case Noise

[RedRacer]

I have a 96 5.0 AWD with 161,000 miles and the transfer case bangs when I accelerate. I am asuming the chain has stretched ?
What kind of transfer case is it ? ( part #)
and what does it cost to rebuild ?
or should I get a new one ?

Whats the best route to take. The truck is in excellent shape and I see no point in getting a newer one. Thanks

 

[Fusion213]

It's a borg warner 4404.
Don't know about the rest.

 

[smiley1]

look at your front drive shaft. Get under there, grab the drive shaft with both hands and shake it. If it is loose you need to replace it. About 200 for the job. Make sure the bolts are tight on the TC side first. This is very common with AWD's.

 

[RedRacer]

96 AWD transfer case

Play is in the transfer case. Disconnected the driveshafts and checked them.

 

[smiley1]

It would be the coupler at the rear of the front drive shaft that goes into the TC. That is where most people have the problems. You may have something different going on.

 

[RedRacer]

Stretched chain and broken tooth on the sprocket. Oh well $847 to rebuild it. Used ones go for $600-$700 plus shipping on the net for a questionable unit and then you have to install it.