I have a 91 pickup. When the truck is accelerating, not if I am driving and let off the gas, the transfer case sounds like it is trying to bind up. It only does it when the hubs are NOT locked and when it is in 2H. If I lock the hubs are locked or put it in 4H or 4L it stops. I can also climb under the truck and turn the front drive shaft (when the hubs are unlocked of course) and it sounds like two gears are just barely touching. I took the back cover off and all the bearings look and feel pretty good. Anyone that has any clue what it might be I am taking all suggestions.

 

You don't mention what transfer case you have: RF1A (4 cylinder) or VF1A (6-cylinder) or auto tranny (unsure what the transfer case designation is). I'm really only knowledgeable about the RF1A and your problem doesn't sound like anything that could go wrong with one of those.

 

I have a 22re so it has to be the rf1a right???

 

I talked to the 4x4 place here in town and they said it has to be the plastic bushings in the t-case, sound right???

 

Unless you also have an automatic transmission.
There aren't any. The only plastic part in a RF1A is the speedo drive gear. There also aren't any "bushings" of any sort, they're all bearings. Part of why Toyota t-cases are so durable.

 

no, its not an automatic. It sounds like the 4H gear is maybe bumping into the side of the 2H gear or something like that.