I just bought this pickup a few weeks ago, I need to update my profile, but it is a 94 3/4 ton 4x4 auto 3.55 (I think) In four high if you goose it from a stop it pops once, in the low side it is much more noticable, if I am appling brakes it pops frequently, and while pulling a load. It doesn't do anything while turning or just rolling a long. When it makes this pop the yoke on the front drive shaft jumps in and out of the t-case. It is like something is binding or jumping a tooth. Any ideas? Thanks
Heath

 

Sounds like its stuck in 4x4. The front axle disconnect vacum motor might be bad or the fork stuck. Sittin on the ground you should be able to grab the front drive line and spin it. Im assuming all 94s have no hubs, just the axle disconect.

 

Well it only does it four wheel drive, not any other time, I well go check and see if I can spin the front drive shaft. I believe the vacum motor and all that has been recently replaced.
Heath

 

Checked the front drive shaft and it spins freely. What do you think the chances are the the chain is streched and just skiping teeth? it has 198k on it.
Heath

 

From what I understand if the chain were that loose it would have exited thru your case already. Describe the drive shaft poping in and out of the TC? are the splines so shot its slipping? or just bound up.

 

Well I am not sure how to explain it. It just bounces or jerks, (hesitates maybe). It only seems to do it under pressure. i.e. in a turn, braking, accelerating. If I try to spin the tires it turns both front wheels, so I don't think it is a broken hub. It is a very loud snap when it does it.
Heath

 

I would suspect a bad u-joint more than the T-case

 

Im kinda at a loss when you can turn your driveshaft freely, but when you, im assuming jack it up and spin one front, both turn. The axle disconnect is supposed to completly seperate the two so they dont bind. Basically it would be like a truck with locked hubs, and that would when you turn on dry ground make it skip and hop.

 

I had the same sound in my T-case, it was shotat 124,000 miles all of the snap rings had broke and made a mess out of the rest of the gears and forks in the thing, it would have cost $900.00 just for parts, at http://www.transfercases.com/ it was only $95.00 more for a new one.