Same freaking sound after transfer case rebuild

[curt93t/t]

So, last summer I decided to send my transfer case to Ninja for a teardown and see if some bearings were causing the sound. Chris said some bearings were bad and did a rebuild. Between having to put everything back together, going overseas, and other issues with the car I finally took it out for a spin. Yup, you guessed it, same freaking sound! Nothing has changed. So the transfer case is still bad (don't think so), it's the transmission (would think the plug would have something on it, but didn't when I drained it for TC removal), or the halfshaft bearing (the bearing where the half shaft mates and bracket bolts to engine block. Not sure if you can really hear it, but tried recording.

http://s1212.photobucket.com/user/st...sound.mp4.html

[donniekak]

Get the car on a lift, or 4 really good jack stands and find where it's come from exactly with a stethoscope.

[curt93t/t]

Already did it. This started when I was in New Mexico and talked the hobby shop into letting me put it on a lift. Had the guy working take it up to 40 and nothing, wondering if it's a load thing. Trailered it this time last year and let it sit for 6 months and decided to do the rebuild.

[Erron Spalsbury]

You, my friend, need a Steelman Chassis ear.
One of the greatest tools I've ever owned. (get the wireless one)

[curt93t/t]

So, the noise starts at 35mph and does not speed up with more acceleration. It does get a little louder, but it doesn't keep on getting louder if you know what I mean. I took it out of gear and it doesn't change. I shut the engine off and still the same. Here's the video with the engine off.

http://s1212.photobucket.com/user/st...94344.mp4.html

[DocWalt]

Have you checked/replaced carrier bearings?

[curt93t/t]

I have visually checked the carrier bearings and from what I can tell (without pulling them) they seem fine. No tears or rips and movement seems within limits.

[DocWalt]

The reason I ask is that I had strange noises and replacing the carrier bearings fixed the issue. I assume we're listening to the "womp-womp-womp" noise in your video? I can only hear "normal" noises otherwise.

[curt93t/t]

I know noise travels and that is why Erron mentioned the chassis ear, but the noise seems to be coming from the firewall area. From where I would need to put the chassis ear I don't feel confident that I would be able to attach the ears. That and out of the 30 years I've been driving this would be the only need, so can't see spending $200+. The womp sound is what I'm talking about. If I decide to pull the drive shaft off and change the bearings can I bypass draining the TC if I just lift the back end of the car?

[DocWalt]

I know noise travels and that is why Erron mentioned the chassis ear, but the noise seems to be coming from the firewall area. From where I would need to put the chassis ear I don't feel confident that I would be able to attach the ears. That and out of the 30 years I've been driving this would be the only need, so can't see spending $200+. The womp sound is what I'm talking about. If I decide to pull the drive shaft off and change the bearings can I bypass draining the TC if I just lift the back end of the car?

I certainly understand the lack of desire to buy the tools, I'm the same way. You can't really get away without draining or topping up the TC, unfortunately. It's much easier to drain the TC first to avoid spillage when you pull the driveshaft.