transfer case

[guidorr73]

I have a np203 transfer case that I believe is making noise. It sounds like a bearing noise. It is perfectly quiet up untill about 40-45 mph. That when it is like a switch turns on and starts making noise. The noise tapers off as you go faster, but it is still there. I pulled it out about a month ago and took it in to one of my local tranny places. First they told me it would be better in the truck to properly diagnose the noise. But i gave them the go ahead to open and inspect it. $300 later and a gasket set, they found nothing wrong. I put it back in and took it back to them, still making noise. Thet said the front driveshaft was hitting the crossmember. Which is true if you really stomp on it. But normal driving it is fine. I even pulled the front driveshaft, locked it into 4wd, and it still makes noise. And it drops out of 4wd when it starts to make noise. They said it was too unsafe to drive. What?!!! So I still do not know what is wrong. I still believe it to be in the xfer case yet. I feel the vibration through the handle. Sorry for the long story. Thanks

[all4fun222]

I had the same problem in my gmc. After many visits to the shop, it ended up being the main set of gears in the transfer case. It is a gear that locks in and out when going in and out of 4 wheel drive. They have to interlock together, if if one is worn when they go to interlock, the teeth grind. What happened with mine is one of them got heated up real bad, and got worn down so when they lock together the teeth are not lined properly. Ended up being about a $1500 job, but all is good now. Hope this helps you. let me know how u make out

[guidorr73]

Thanks for the feedback.
At this time I think I am going to drive it with the noise and all. It's just too darn cold to be messing with it now. It was a job the first time I pulled it when it was warm outside. I don't drive it much, only if there is snow or something to haul. Come spring I might tear it down myself. Any way I can save a buck. Again thanks for the reply.