Thanks for the tip on the removal of the fill plug first. I did buy the oil but its about 5 degrees out so I have put the truck in my shop to thaw it out till tomorrow night after work. I am still going to do the oil change but could I put the truck up on jack stands and put it in drive to hear the noise. Then could I pull the transfercase and just put the transmission in gear and see if it goes away. I didn't know if you could shift the trannny with the transfercase off or not. I am just scared about spending the money on a transfercase and it not being the problem.

 

ON the t-case; I know this is a risk, however my local salvage yard has about 5 Disco 2's in it for C4C. Transfer case intact. I pay $250 for transmissions and $150 for transfer cases. Might be worth it to take a look.

 

The transmission turns the transfer case.
If you want to narrow it down just remove the driveshafts then put it in gear and see if it still makes noise.
Then shift into lo gear, then lo locked and hi locked then back to hi unlocked.
See if the noise changes with each gear range on the t-case.

 

Well I changed the oil last night and there were no shavings in the old oil. I put new 85w/140 in and was hoping that would make a bid enough difference that I would then know it was for sure the Tcase. Started it up and had the same whinning sound in both high and low. I had it up on jack stands so I had my brother stop and start the wheels while I listened under it. It sounded like to me it was coming more from just in front of the tcase like right where the front drive shaft connects to it. I had just put a new Tom Woods shaft in somtime in the fall and had only greased it twice so I though maybe it was bad or needed grease. I stopped the motor and tried to turn and twist the shaft looking for loose, bad or nosie coming from the ujoints had none. Last I thought I would disconnect the front shaft from the Tcase and see if this made a diference or at least would pin point me in a better direction. Sure enough it was my brand new front drive shaft. I still had my old one so I put it in and the noise is now gone saving me 1,300.00 for a rebuilt Tcase. The noise was coming from the big ball bearing looking object in the center of the two ujoints. I have now found out that this needs to be greased with a grease needle but did not see this in any of the instructions sent with it. I think I am going to send it back and see if it was damaged or if it is ok like it is.

 

They have directions how to grease the centering ball. You need to take off the rear of the driveshaft off so you can articulate the driveshaft. You need to get one of those pointy grease attachements for your gun not a needle though.

 

Send me your tele number and I'll call and walk you thru what to check and were to buy a used one in the $400 plus range.

 

U-joints need to be greased at EVERY oil change.
Unless you are the one greasing them then they are NOT getting done.

 

If you need a good used 04 t/case, I saw one posted yesterday.
Look closely at the oil for bearing material or metal chunks. If any other then the normal build up on the magnetic drain plug, don't plan on much more use from that t/case.
Do you know where the fill plug is, exactly, if not find it before draining or you will get in trouble.

 

Guys, he wasn't greasing the centering ball in his NEW Tom Woods front shaft. That is what was making the noise....

 

Yes that was the mistake I didn't do which was grease the center of the shaft. I never read or saw any directions on doing it. I guess it is somthing you are suppose to know, now I do. I was looking at it yesterday and am still not sure how to pack grease into it with out it just flying all out. The center ball also has a few scratch marks on it and I am not sure if it ever got hot or not. Should I send it back to get looked at or just try to grease and use it.