Sir William
Active Member
Mine does the same thing. If there's any load in any 4x4 mode and lack of traction in the rear, I'll get a loud POP from the transfer case as it applies power to the front. I'm guessing the chain has stretched after > 220K miles and is jumping a tooth. My hypothesis is that since the case was always in 4x4 Auto (no 2WD option in 1999), even turning in parking lots would put a little stress on the chain which slowly stretched it over time. I can validate this because with the fuse out or BWM done, it's much "smoother" turning at slow speeds on hard surfaces. So to those who haven't done it, do it!
The choice now is to rebuild a TC with more than a quarter million miles on it or swap in a lower mileage unit. The latter seems to make more sense.
The choice now is to rebuild a TC with more than a quarter million miles on it or swap in a lower mileage unit. The latter seems to make more sense.