T-case clunking loudly.. (help, need answer quickly)

[uglykid]

My old t-case had bad output bearings and I swapped in one used from a parts recycler.. ('95 Explorer BW 4405-07, replaced with '96 same model)

The new t-case makes a clunk-clunk-clunk like a slipping posi unit at low speeds when it's cold. (well, I say low speeds, because I will not go over 20 mph with it clunking like that) I can feel this kicking my feet through the floorboard.

The noise stops as soon as I put it in 4wd and usually returns shortly after going back to 2wd, until driving 2 miles or so. Then it just seems to go away and not return till being parked for several hours.

After searching here, the only thread I found with a similar noise description mentioned that "low fluid makes the clutch try to engage" so I immediately drained (fluid was low and dirty) and filled the t-case with fresh ATF. Took it out for a test spin, and although less, it still made the noise.

Is this something that will clean up when all the gunk is worked out of the clutches inside the t-case, or a sign of a problem?

Unfortunately, I need to know the answer pretty quick, as it has a 7 day warranty and I'd have to pull out the t-case and return it by tuesday 10/27..

Thanks,
Dave

 

[gmanpaint]

Take it to the place where you purchased it, take one of them for a ride.
If they are honest and care about their service, they will work something out with you.
If you feel that you got a bad case, remove it, and demand another case in return.

Unfortunately, you might have to go threw a few cases b4 you find a good one. This is the game of chance the salvage yards play on a daily basis. 7 days seems pretty short time frame for a warranty. I got 90 days minimum, and for an extra $75 a full year. My first case was bad, and had to get another.

 

[uglykid]

Kind of hard to take them for a ride, as it goes away in about 2 miles..

But I had thought about calling them, and telling them that if they'll extend it another week, I'll try troubleshooting it instead of just swapping it out again.

But.........

Back to the original post, is this something that clears up when the detergent cleans up some mung, or is it an future failure? If it's a future failure, then I'll not waste my time, and yank it back out.

 

[uglykid]

Update, the pressure is off. I called the yard, and they have extended the warranty, I guess I get to find out for myself if it's an long term issue.

Thanks for the help..