Transfer Case Replace and Clunk

[adampwilliams]

I've seen posts somewhat mention this. But, ever since I"ve had the gladiator it will buck a little bit when down shifting and make a clunk. Sounds like slack in the transmission or transfer case. I installed a new Adam's drive shaft thinking that would help, but it didn't. I've now started feeling a grinding/vibration on a casual stop. It sounds like something is rolling around in the bed of the truck. Jeep dealership is being kind enough to replace the transfer case for me under warranty. But, just wondering if anyone else has replaced their transfer case and had a more smooth transition when the transmission is downshifting automatically.

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[Hootbro]

Are they sure it is the transfer case? I have an appointment this Friday to take mine in for rear end clunk and I am about 90% positive it is an excessive pinion backlash issue in the rear diff.

 

[adampwilliams]

No. I don’t think they’ve nailed it down. But, I’m all for a new transfer case if they want to give me one. Yeah, definitely feels like it’s either transmission related or gear related. Who knows.

 

[adampwilliams]

No. I don’t think they’ve nailed it down. But, I’m all for a new transfer case if they want to give me one. Yeah, definitely feels like it’s either transmission related or gear related. Who knows.

What’s the fix if it’s pinion related? New gears? Or is it a simple tightening of a bolt or something?

 

[Escape.idiocracy]

What’s the fix if it’s pinion related? New gears? Or is it a simple tightening of a bolt or something?

I’m taking a stab- but when guys were having axle seal leaks they were replacing the entire housing ?

Re-shimming the pinion/carrier would correct the backlash issues. Depending on how long it has been an issue and what the wear pattern….. may or may not need new gears.

 

[Hootbro]

What’s the fix if it’s pinion related? New gears? Or is it a simple tightening of a bolt or something?

What @Escape.idiocracy said about re-shimming the pinion/carrier assembly would correct it. The problem though is that is pretty specialize skill set and many dealerships do not want to mess with it and a good chance since under warranty, will push for a new whole rear axle assembly.

 

[jac04]

The rear end clunk seems to be common. Both my JKR and JTM have about the same amount of 'clunk'.

More info here:
https://www.jeepgladiatorforum.com/...reverse-2020-jtr-automatic.57350/#post-940551

 

[adampwilliams]

Are they sure it is the transfer case? I have an appointment this Friday to take mine in for rear end clunk and I am about 90% positive it is an excessive pinion backlash issue in the rear diff.

Did you get yours fixed? Transfer case didn’t fix anything.

 

[Hootbro]

Did you get yours fixed? Transfer case didn’t fix anything.

No and my assumption on pinion backlash was unfounded. Before I took it in for the dealership appointment, I took the rear diff cover off and actually checked the pinion backlash and it was at 0.006" which is right in the middle of the spec.

Following @jac04 link above while I had my diff cover off, I checked the e-locker and seen the loose spider gear engagement that was mention for it and that seems to be my noise in my case.

I kept my dealership service appointment anyway and they pretty much said the same thing. They even had a fresh off the delivery truck Rubicon JT like mine and let me drive it on their lot and it had the same low speed clunk as mine.

In my case, I just think that is the way it is for those at least with the rear e-lockers. I have stopped dwelling on it and at least have a documented service visit for it.

 

[ShadowsPapa]

I’m taking a stab- but when guys were having axle seal leaks they were replacing the entire housing ?

Re-shimming the pinion/carrier would correct the backlash issues. Depending on how long it has been an issue and what the wear pattern….. may or may not need new gears.

My understanding was it wasn't the housing but the entire assembly that was replaced......... they don't want those people setting up used gears in a new housing.

 

[adampwilliams]

No and my assumption on pinion backlash was unfounded. Before I took it in for the dealership appointment, I took the rear diff cover off and actually checked the pinion backlash and it was at 0.006" which is right in the middle of the spec.

Following @jac04 link above while I had my diff cover off, I checked the e-locker and seen the loose spider gear engagement that was mention for it and that seems to be my noise in my case.

I kept my dealership service appointment anyway and they pretty much said the same thing. They even had a fresh off the delivery truck Rubicon JT like mine and let me drive it on their lot and it had the same low speed clunk as mine.

In my case, I just think that is the way it is for those at least with the rear e-lockers. I have stopped dwelling on it and at least have a documented service visit for it.

Thanks for the update. The issue I'm having now is a grinding sound while coming to a stop. I did put in a new Adam's driveshaft and thinking they possibly didn't tighten the yoke down good enough. I'm fine with not worrying about the Clunk as well. Just annoying when I drive friends JL's and they are super smooth

 

[Hootbro]

Thanks for the update. The issue I'm having now is a grinding sound while coming to a stop. I did put in a new Adam's driveshaft and thinking they possibly didn't tighten the yoke down good enough. I'm fine with not worrying about the Clunk as well. Just annoying when I drive friends JL's and they are super smooth

Yeah, grinding sound is a different ballgame from a clunk noise. Hopefully you get that figured out.

 

[adampwilliams]

Jeep flashed and upgraded my TCM software. Clunks are 90% better. So, if you’re having hard clunks when putting into reverse after startup, coming to a stop on a down shift, I’d definitely start with this cheapest option.

 

[Newlife]

Did you figure out the grinding noise? Mine is doing it now on a slow down 21 jtr with 20,000. Just started after an off-road trip. Had three shops check exhaust, removed skids, spare tire, drawer, fridge, spare tire, spare tire heat shield, and license plate. Cannot find anything loose or rattling externally. Sounds just like an exhaust rattle but everything the exhaust shop looked out couldn’t find anything loose or broken.

Made an appt with the dealer incase it’s something more severe but it’s not until next Friday.

 

[adampwilliams]

No. Never figured it out. It feels like it’s my rear spring. It really hasnt gotten any worse. So, I just turn the radio up at this point. My next check was going to be to remove the springs to make sure the isolators are on correctly. But, springs are the only thing left I can think of.

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