Truck drves fine at speed.u joints are good.also the rear end checks out ok.there is a clanking noise coming from the transfer case at lower speed and decelaration.i can see a tag on the transfer case that says new process gear and that it has been apart at one time.ive never attempted this type of repair before.any good advice.
Thrust bearings can cause gears to grind into the case when they go bad. The chain may be stretched too. If you have the same size tires on all four, change the 2 rear tires to a slightly larger size. This puts tension on the chain so it won't drag on the inside of the case.
SOURCE: High pitch noise.
Did you check that the noise it is not just the serpentine belt slipping on the alternator pulley.
In this case you fix it by replacing the serpentine belt or putting in tension the pulley arm.
The transmission usually does not make high pitch noises, rather scratching noise when it is faulty,
SOURCE: what type of oil do i need for a 1995 chevy
The transfer case uses two types of oil one is automatic fluid the front part of differential takes gear oil 85/120 wt. both differentials I would use synthetic oil and would run 85/120 however if the rig has been well used you might want to go with a higher weight oil oil so you don't get wheel seal leaks.
SOURCE: 2003 chevy 1500hd 4wd transfer case problem
your gear box needs a good look .. could turn out expensive unless you can manage with patience.
SOURCE: i know nothing about trucks
The truck shouldn't be driven if the transfer case is low on fluid, so yes the yoke must be installed if you want to drive it without risking damage to the transfer case and possibly transmission. There should be ATF in the transfer case not gear oil.
SOURCE: 99 Z-71 extended cab. Cracking or Clanking when
Most likely the U-Joints. It shouldn't be driven until they are fixed. You can check them by crawling under the truck and simply grabbing the driveshaft and turning it with your hand. You'll be able to see right away if they are tight or sloppy. Any slop at all means the U-joints are bad. Make sure to set the parking brake first and put the truck in neutral before crawling under it.
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