heres the story. i took my 95 chevy tahoe 4x4 into a mufler shop to get a new mufler put on. when they take it off the lift i drive off and durring acceleration it grinds like crazy. sounded kinda like i didn't have it fully disengaged out of 4wd. i mest around with the floor shifter and got nothing. it was still grinding and clunking when i would accelerate. so then i put it in to 4wd and punched it. no grinding. it worked fine. i take it strait back to the mufler shop to tell them they screwed something up but they say the didnt do it. so i have no clue whats wrong with it. to get it home i put it in 4wd to get going so it would not grind then put it back into 2wd and took it easy to not over accelerate and make it grind. after the 20 min trip on the hiway in 2wd i decided to leave it in 2wd and try it again. it worked fine. then as soon as i took a corner it started back up again. any clues???? i have no idea. please give any advise you have

Sounds like maybe your front end isn't disengaging. IF you have manual disco's check to make sure they are unlocked

there not manual. and i can alaso turn my front drive shaft when its in 2wd so i know its disengaged.

How do you know it's the transfer case? If you can turn the front axle, you know it's disengaged, if not, try taking out the front actuator and see if that makes it stop (keep in mind that diff fluid will come out so don't drive far). It may be your transmission or your t-case, but you should check for damage underneath, the guys at the muffler shop may have messed something up on accident. Just make sure they did before you go accusing them of it.

first off, get under and make sure all the new exhaust work is away from the frame, suspension and other parts of the truck. also check hangers.

as for your tcase, since it is in 2wd, go to the front diff, pull the actuator AND the tcase switch which is the other little screw in thing on the diff. if that switch is busted, it might not be disengaging completely which allows the gears in the diff to grind and/or stay engaged...i know, i had that problem.

if thats not it, check to make sure your tcase lever and linkage is adjusted properly.

i checked underneath and so no signs that the mufler shop had messed anything up but i did see one thing... there is what looks like a vacuum hose that just ends and dosnt connect to anything. i couldnt see exactly where it was coming and im not sure what its for. is there a drain tube or something that comes out of the transfer case or trany??? it hangs down right by the shift linkage for the transfer case and its cut on the end at an angle.

thats your tranny vent, its suppose to be there.

the noise isnt coming from the front diff. its coming from the transfer case. i even hung out of the truck while my wife drove and listend and felt that it was coming from the t-case.

My tcase was making some grinding noises as well. It was just the fluid was low. I replaced the rear seal and refilled it. It's amazing how quiet it is now. Good luck

i figured out how to fix it. i went to a transmition shop they fixed it and i paid $150. [img]images/graemlins/grin.gif[/img]


it was a broken ring