I put my dual (top shift) cases together a few weeks ago and I have a new noise on the road, now. When driving in 2-Hi-Hi, I hear what can best be described as a random 'clacking' sound coming from the area of the cases. It sounds like something is flying around in there. It only happens under light load / cruising. Doesn't happen under hard acceleration (not that my stock 22RE really accelerates 'hard') or when coasting in gear or in neutral.

I haven't had it off road yet and I'm not sure I trust to go.

The rear case is a MC rebuild with about 10 k on it over four years. It ran fine before the swap so I don't think it's the problem. The crawl box is built on an MC07XD dual adapter using a t-case I picked up from a used truck I know nothing about but it looked to be in good shape when I took it apart

Shifters are 'triple sticks' and are not hitting the body anywhere. I still have the stock cross member with a single t-case mount on the front case.

I followed the MC and TG directions when assembling the crawl box and I don't think I forgot anything when I built it. Any suggestions before I take it out and apart?

Thanks.

 

It could be a number of things.... i would make sure you put all the detent ball bearings back in for starters. Got video of the noise?

 

Thanks. I need to test it in hi-hi, hi-lo, lo-hi and lo-lo to see when it makes the noise, etc. Will check detent balls if I can get to the plugs but the shifters all feel 'right' and the click / detent as they should.

 

You need to test it under load and see if anything pops out of gear or doesn't act right.

Dual cases make LOTS of non typical noise compared to your single case.

:wabbit2:

 

Thanks. I had it out on a local sand pile today and it seemed fine. I have no front driveshaft right so I need to get that in before I can test it fully.

The triple stick shifter boots are a bit tight and I think they may have been preventing full motion of the shifters. Will try removing them and see if that helps.

Duals are definitely noisier and 'clunkier' than a single case. I added a TG dual case skid plate today but I only have the front OEM t-case mount in right now. Will add the second one and see if that helps tighten things up a bit.