Transfer Case "Death Rattle"

[AlisoBob]

I got my truck pretty cheap ($16k) because the drive train had a pretty nasty rattle, the guy even thought the motor might be blown up.

The real cause? The mechanical transfer case linkage was buzzing... Heres the cure, my truck is silent now.... SWEET!

Repair:

Bend the shift lever spring reaction tab outward to increase the spring tension on the shift lever.

Raise vehicle on a lift.
Locate the shift lever spring reaction tab on the shifter lever assembly (fig 1).
Using a suitable pry bar, bent the tab outward approximately 1/4 - 3/8 in (fig 2).

[Tow Master]

Sweet! Whendid the truck do the rattle? I have heard of this before and its good to know its fixable. Im guessing you posted pics? Try to load them up! If anything make a account with photobucket.com! Thanks!

[AlisoBob]

Originally Posted by Tow Master

Sweet! Whendid the truck do the rattle? I have heard of this before and its good to know its fixable.

My truck did it under moderate acceleration mostly, sometimes when cruising.

You can place your hand on the lever to stop it, bending the tab places more "detent" on it to do the same thing.

Looking on the net found a few more "Fixes"...

Symptoms:

Buzz or clatter from the transfer case. A summary is that the lever passes through a bracket with a plastic liner to prevent the lever from hitting the bracket. The liner does move in time and the result is the buzz or rattle is the sound result.

Repair:

Shift the lever to 4L.
Remove the knob, boots and pry up the liner.
CLEAN EVERYTHING WITH CLEANER - REMOVE GREASE AND OIL PUT THERE TO STOP THE RATTLE IN THE PAST.
Apply a small strip of RTV sealer on the bracket
before RTV sets up, press on the (clean) liner making sure it is snapped into place.
Replace the boots
shift the lever to 2H
put the knob on
"...DO NOT MOVE THE SHIFTER UNTIL RTV IS CURED, DON'T SHIFT INTO 4H, N, OR 4L FOR 24 HOURS".
This is for Cummins equipped 4X4, but I would suspect the most mechanical 4X4 transfer cases are pretty much the same.

And

Subject: [RAM] Transfer Case Shifter rattle



To eliminate that annoying Transfer Case Shifter rattle - you need one spring PN 4301631, designed for Mitsubishi 3L engine exhaust flange. (NOTE: this is a Chrysler part number for a Mistu four cylinder exhaust flange bolt spring.)

Insert spring between the shifter and the mounting bracket at the bottom, so that the tensioner spring already on the shifter unit captures the new spring, that is, keeps it in place with the stub ends of the tensioner that stick through the shifter and bracket.

Fix is courtesy of Craig Graunke, Chapman's Las Vegas Dodge, master diesel technician.

[DuramaxNoKaOi]

Thanks Alisonbob, I really notice the rattle in my truck during acceleration or under load. Makes me crazy, put your hand on the shifter and its gone. If it wasn't 30 out I'd be bending the tab now

Got a fix for the rattle coming from the driver side window at 50+?