whats the sound of intermediate bearings going bad

new update, new exciting noise!!!!

coming to a stop, push in clutch and as I am moving i hear what sounds like straight cut gears hitting on something. Doesn't stop until driveshaft stops. I put my hand on transmission and can feel it, i put my hand on the shifter mount for the transfer case and can really feel it. As i rolled down my street it stopped making noise, but it will be back.

When it cools down or tomorrow I will pull the transfer case pan and really examine it. I dont want to wreck the case or the gears, but something is wrong.

Other than the P/S pump, its the very last thing not rebuilt. stay tuned!

 

Alright, we have all seen this before. I got some questions though because I have never done a proper rebuild of this D18 or any other.

Output shaft sliding gear will cock about 1/4 inch on the outside of the teeth when pulled by hand. It might be a bit less, but this seems like a lot.

Output shaft gear, the small helically cut one on the same shaft as the sliding gear, will hit the case by hand. I think this is bad and I believe this is the knocking noise I hear as I let off the gas. The gears unload, unmesh slightly and the force drives it into the case, making the knocking noise. Don't know why it would do that.

The intermediate gear set moves a bit back and forth. Doesn't make any noise or look like its in bad shape.

Cant figure out hat the crashy noise is or was. The shift lever was in correct spot, no pieces of gear floating around, but plenty of brass.

Whats my next step guys? I know I need to rebuild it because something is wrong, but I am very concerned about the lateral movement of the sliding gear.

 

I poured the oil I drained out of the transfer case right back in. Its got brass in it. Its like panning for gold. Drove it around and made the same noises. I have decided that I will be rebuilding a large hole dana 18 with the 1 1/4 intermediate shaft. I will be getting the rebuild kit from Novak. When i start I will make a new thread because I might need some help and if nothing else some of us can learn something new.

 

When you pull that bearing out you will see how bad the shaft is worn.

 

Howard. Thank you so much for linking your pictures. I got a bit overzealous yesterday and tore apart my extra big hole 1 1/4 intermediate shaft D18 with no pics or documentation. Thought to myself "that was dumb". Not the first time.