2004 Dodge 2500 4x4 cummins, 183,000 miles.

About 3 weeks ago i had a friends shop replace my front axle ujoints. They had never been changed and had started to squeak when i turned so we went ahead and changed them. Probably a week went by and we had some snow one morning, so i used 4x4 for the first time since the new ujoints. When i first started moving i heard a little noise, kind of a rubbing, grinding kind of sound for just a few seconds and it was gone. No more noise for the rest of the drive to work.

Then this Sunday we had some more snow. I pulled out of the driveway, shifted into 4 high and immediately heard that same scraping, rubbing sort of noise. It reminds me of the sound your brakes make when the pads are gone, a metal to metal rubbing grinding sound. This time the sound didnt go away, it was here to stay.

I have found the noise is much louder when you are on the gas, very faint when coasting. I can very slightly hear the noise in 2wd also, but nothing close to like it is in 4wd. You can also feel a very slight vibration in the steering wheel.

Today the truck was back at my buddies shop for him to figure out what was up. They replaced the ujoints in the front driveshaft which were showing a little wear. This did not help at all. Drained the front diff, everything was good, no metal shavings, replaced the fluid. No play in the pinion bearing either.

I am starting to think the noise is coming from a problem with the new axle ujoints, i never heard this noise until we replaced them, it gets loud and has a little vibration when you accelerate like a ujoint going bad would, and is almost silent when you coast. Does this sound right to anyone? What about the front unit bearings, they are original, but seem fine, and they should make the same noise whether you are in 2wd or 4wd.

Sorry for the long post, just trying to get some ideas of what to check next.

 

I am in the same situation as you. I just had u joints replaced, however I think that may just be a coincidence. I am thinking it could be a few things, either transfer case chain or snap rings. Let me know if you come up with anything . I am taking mine to the shop this week to see what is wrong. I have pretty much the same truck setup as you too with same mileage.

 

Its was chain in the transfer case. With the truck up in the air and running in 4wd you could put your hand on the bottom of the case and feel the chain slapping. It hasnt skipped a tooth, never popped or banged, just rubbing the case. For right now i have the front driveshaft pulled out to reduce the noise. We will tear into the case this coming week to figure out if just the chain can be replaced or if i will need more.

 

Just got mine in to the shop. He is taking it apart now. Said a new Jasper transfer case would run about 1950 installed. I am hoping though he can just replace parts. Any update on yours?

 

Jasper does not make a new T-case. They are all rebuilt or as they say "remanufactured". If their T-cases are anything like their remanufactured engines they are junk. You will also play Hell getting them to honor the warranty. I have had a number of friends and friends of friends that were told to shove it when they tried to collect on the warranty.

 

Mine should be going to the shop tomorrow. I ordered the chain hoping that would fix it.

Just an FYI that price sounds way high for the t-case and install. Check out this site http://www.moparonlineparts.com/part...layCatalogid=0 If the chain doesn't fix mine, i plan to order a new case for $778.

 

OOPS... yeah I meant to say a remanufactured Jasper. Thanks for the info on them, I don't know much about Jasper products.

KYLE... Thanks for the website. Let me know if you order anything through them.