New noise after teardown of Transfer Case

[yohe]

I just got finished replacing the Speedometer Drive Gear in the TC and everything went back together nicely. I went to take it for a test drive and it has developed a (best described as) a "whirring" noise that seems to be coming from the front of the transfer case. I had the case off originally to fix a jumping speedometer/gear hunting issue and now this. When I had it apart everything looked to be in very good shape and no metal shavings or discoloration of the fluid. The chain was tight and not signs of abnormal wear except for the gear I replaced. It is a '96 4.0 OHV with the 4405 case. I just had Ford replace the tranny when all of this started about 2 weeks after. I hope this isn't a dumb question, but is the front drive shaft supposed to spin when it is set in 2WD? And also I noticed that when I went back to recheck after hearing the noise the shift motor pin is at 4 HI. Shouldn't it be at N when it is set to 2 WD. This is new to me, I never worked on a Transfer Case before and thought I could do it. This sucks! I just got it paid off!!

Thanks
Mark

 

[je5]

The shift motor is in the right location, if it were in neutral you couldn't power it and the vehicle could roll off. Check and let me know how far you can wiggle the rear output yoke up and down on the TC cause I suspect you have a worn case at the output bearing and this also could have caused your speedo drive to wear out.

 

[IZwack]

If it didn't whirl before, but did after, then chances are, it was something during re-assembly.

As stated, the shift motor is pointing towards the correct direction.

 

[yohe]

new noise

I have already checked the rear and front shafts for any play. There is a slight wiggle on both. Maybe less than an 1/8th". After doing some more searching on the board between under the hood and transmission and cases, could it possible be a u-joint at the case end since the sound is loudest at the case?

Thanks for clearing up the motor position for me.

By the way just for the record, this site kicks a$$. I got to meet some great people at the All Ford Nat's in Carlisle PA a few weeks ago and I have used a lot of the info I have found on this site to fix other issues. Not to mention sold and bought a few things. Any way just my way of saying thanks.

Mark