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4 Wheel Drive/SUVs/86 Jeep Cherokee Trans/Transfer Noise

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Expert: - 8/30/2004


Question
I have a 1986 Jeep Cherokee 4x4 with a 2.5 cyl, 5 speed/NP 207 Transfer with 190,000 miles. When you pull out in any gear there is a noise from the trans/xfer area. It happens in 2 wheel, 4 wheel high. NOT in 4 wheel low or with the xfer in Nuetral and the trans in first. I gave the vehicle to my son and he is in PA and I am in MO trying to help him. I was initially leaning towards the release bearing But now I dont know. Any thoughts?

Answer
Ray,

Without, actually listening to the noise, or driving the Jeep, it's hard to guess what the problem is.  I would suspect a bent or worn shift fork, which could cause the high range gears to not mesh properly, or a broken synchronizer stop ring.  These are just a couple of items that could cause this problem, as this case has numerous thrust bearings, washers, etc, that could show a lot of wear with this many miles.  

The first thing I would do, would be to change the oil in the transfer case, and look for broken parts, metal filings, or debris in the old oil.  This could give you a clue to a broken component.  

Then, if you are sure that it is a xfer case problem, I would consider pulling it out, and take it in to a reputable transmission shop to have it rebuilt, unless you feel confident rebuilding it yourself.  Another option is to find a wrecking yard, and purchase a used transfer case.

Chilton prints a fairly good manual for your Jeep, and is a great troubleshooting, and repair guide.  It shows a complete exploded view of the NP207 transfer case, along with disassembly, and assembly instructions.  The book sell for, around $20, and is available at most auto parts stores.

Carl  

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Carl Brandt

Expertise

Will discuss suspensions, lifts, lockers along with tire suggestions. Trail ratings and possible requirements needed for specific type of trails. Safety equipment and what you should carry with you. Certified off-road instructor. I am not a mechanic, and 4-Wheeling is a hobby, so if I can't answer a technical question it is due to my mechanical knowledge being related to vehicles that I have owned, or have worked on. I do not have manuals on all vehicles.

Experience

40 plus years of 4 wheeling in a variety of vehicles. At the present time, my major off-road rig is a 94 Jeep Wrangler with a spring over and a 1 1/2" suspension lift. This gives me a total lift of 7" or so. I have lockers front and rear. I have removed the track bars, and sway bar for maximum articulation. I am running a stock 2.5 ltr 4 cylinder with a Jacobs ignition along with a cold air high flow filter. It has 4.56:1 gears with a Dodge NV4500 transmission along with a 3.8:1 Atlas II transfer case. This gives me a final ratio of 105:1 in low gear/low range. Other vehicles I own, are a 96 Ford F-250 with a 6" lift, posi rear end, 36" Hummer tires, 5 speed with a fuel injected 460 ci engine, an 87 Samurai with an 8" lift, Ford 9" rear end with a spool, Chevy Dana 44 front end with an electric locker, 5.88 gears, 16% reduction in high range and a 6.5:1 low range with 35" Baja Claws, and a stock 2003 Grand Cherokee Overland. Trails I have run are the Rubicon (10 times), Dusey Ershim, Fordyce Creek trail, McGrew trail, several trails in Moab, Utah along with local monthly runs.

Organizations
Lost Coast 4x4's Cal 4-Wheel Corva UFWDA Blue Ribbon Coalition

Education/Credentials
Certified off-road instructor - Certificates in engineering/electronics

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