Well, I just finished up installing the Diff-Lok cable for the front axle. Now my transfer case is making some horrible sounds. The truck has 225,000 rough miles on it, so I'm wondering if it is just the chain loose or something. It seems fine when I'm in 1st gear taking off but when i shift to 2nd and let off the gas or coast it will make a grinding/popping sound. I think the transfer case is the NV241D but not 100% sure. Let me know what you guys think, thanks in advance.

 

Do a search on the snap ring on the back of the t case. Sounds like yours may have broke.

 

I thought my t case was grinding when actually it was the cad. Are you sure it is not the cad trying to engage ?

 

If it was not making noise before you changed it its the front axels not fully engaged

 

Well, I took the front drive shaft off the truck and the cardan joint was totally gone. The little ball in between was so wore out that when I took it apart it just fell out. I went to O'rielly auto and got a whole new drive shaft for $200...it also have grease zerks for all the joints....now it works perfect.