HELP! Very noisy transfer case

[KINGBYNG4]

Hi everybody. I have searched high and low all over the internet, and have not found a similar enough situation to confirm my problem with any certainty. I was driving my 1997 Talon TSI AWD pretty hard and everything was fine. Then this horrible clunking sound started happening. It only happens when I'm in gear and under acceleration. Not when I'm coasting or on the brakes. The sound is dependant on speed not engine rpm and happens in every gear. It sounds like its coming from the passengers side under the floor and is harsh enough that I can feel the vibrations through the steering wheel. I'm thinking its probably the transfer case, or drive shaft but I'm not certain. Any help would be appreciated greatly, and please let me know if I left anything out that would be helpful.

 

[pauleyman]

Did you at least crawl under and look. Could be 100 different things and your description isnt enough to point to any one item. Crawl under and look for obviius. Drain trans and transfer caae if necessary and look.

 

[KINGBYNG4]

I did look under, sorry forgot to mention. Nothing appeared out of place. I will get more into it when I have more time, but as for now, I took it out because I was curious to see if wherever it was, was something that was noisy but not nessecarily fragile. I went into boost for about 2 seconds and the sound is noticeably worse and now happens when coasting in neautral and will happen when i push the car when it's turned off. Please don't tell me what was a stupid idea, I was fully prepared for something in the drive line to blow, and I figure weather its the trnasmission or transfer case, I'll be replacingg the whole unit, as I have not been able to successfully rebuild a transmission before.
The sound is cyclic. That is, it happens in a repetitive manner, it is a loud knock roughly every time the wheel turns over. Since it happens when the car is in neutral and in all gears, I am hoping it is the transfer case, although I don't fully understand how transmission work, but based on this description it could potentially be something with the output shaft in the trans right? Also, I can feel resistance when I push the car in neutral just before the clunk happens.
Something else that may be helpful is that the sound is not as apparent when reversing, even if I'm accelerating in reverse. Hope this is some more helpful info to go off of.

 

[pauleyman]

If it happens at slow speed puahing check the axle particularly drivers side axle and make sure the intermediate is still bolted.

 

[KINGBYNG4]

It happens at any speed. Even just pushing it at 0.5kph. I will check the axels when I get home. I was thinking I could disconnect the drive shaft and either drive it or push it in neutral. If the drive shaft is off, and car is in neutral, am I right in assuming the gears in transfer case will not be turning?

 

[KINGBYNG4]

Update.
So I'm starting to get bummed out, I took the drive shaft out, and its not the u joints or bearings in the drive shaft (forget what they're called.) And its still making the clunckidy clunck. The axles look fine, but I didn't take them off or anything. I really don't want it to be the trans, cause those things are costly. Could it be the transfer case still? Just to clarify, the car still makes the sound as it did before (well actually its worse, but I dont believe its due to me taking out the drive shaft. Now the car will actually get stuck when I'm coasting slowly, weather its backwards or forwards, neutral or in gear.)
I'm really at a loss here and still can't find any info about a situation like this online.

HELP PLEASE!!!!

 

[pauleyman]

Well take the tcase off and spin it. If that isnt it only two other possibilities

 

[KINGBYNG4]

Update.
I now have the drive shaft and transfer case off the car. It is still making the clucking unfortunately.
I would like to think otherwise, but I'm fairly certain it's the trans at this point. It could possibly be the right axle, but is definitely coming from the right side so is not going to be the left axle. If anybody has any idea what specifically it could be, please let me know. Is there a weak point in these transmissions? It seems weird that the trans blew when I'm only pushing 15psi, and it did not occur during a hard start or anything. It happened after a long straight away.
Please let me know if you have any ideas of what it could be, and if you have any good sources for a used trans for a decent price. Thanks for any help!

 

[boostdawd]

Sounds like the front differential in the trans. Drain the oil and see if it appears metallic. U can also remove the 5th gear cover on the end and look for chunks. This happened to me recently and was making weird noises like u described as well as tension in the drivetrain. Whenever something goes wrong on my car I think the worst. If it turned out to be smaller issue than what I thought well I celebrate a bit .

 

[pauleyman]

Update.
I now have the drive shaft and transfer case off the car. It is still making the clucking unfortunately.
I would like to think otherwise, but I'm fairly certain it's the trans at this point. It could possibly be the right axle, but is definitely coming from the right side so is not going to be the left axle. If anybody has any idea what specifically it could be, please let me know. Is there a weak point in these transmissions? It seems weird that the trans blew when I'm only pushing 15psi, and it did not occur during a hard start or anything. It happened after a long straight away.
Please let me know if you have any ideas of what it could be, and if you have any good sources for a used trans for a decent price. Thanks for any help!

Is there a weak point? Well here is my opinion. Most guy i know do no maintenance to the trans. They might change fluid but thats it. Trans items wear like any other. I have show many guys severe issues with bearing play when i changed a clutch for them. None made any repairs because the trans shifted into gear well. Guess what happened. I check bearing play when i change a clutch. Given the age of these cars i know few units that have under 100k. Now there are definate weak points in the trans but for a mostly stock car this is probably a larger source of faulure for most. Drain the trans. If its shiny or chunky you have work to do. I seriously doubt its the axle

 

[Eddie Tsi]

Update.
I now have the drive shaft and transfer case off the car. It is still making the clucking unfortunately.
I would like to think otherwise, but I'm fairly certain it's the trans at this point. It could possibly be the right axle, but is definitely coming from the right side so is not going to be the left axle. If anybody has any idea what specifically it could be, please let me know. Is there a weak point in these transmissions? It seems weird that the trans blew when I'm only pushing 15psi, and it did not occur during a hard start or anything. It happened after a long straight away.
Please let me know if you have any ideas of what it could be, and if you have any good sources for a used trans for a decent price. Thanks for any help!

Check your trans like suggested, also it be as simple as a bad wheel bearing.

 

[KINGBYNG4]

I'll check the under the 5th gear cover. I know the oil will be sparkly because 2nd sincro is done and second grinds a lot, but if I see chunks I guess I'll know what's up. If It's the differential can I replace the diff without replacing the whole trans?
And no I could not be a wheel bearing, they have no play and spin freely when off the ground. Wish that was it though! Thanks for the help guys.

 

[boostdawd]

You can just replace the differential but is not an easy task. I would send it in to get done or take it to a reputable member to have the work done.

 

[KINGBYNG4]

If it's a difficult enough job that I should send it to a shop, I will probably just try to find a used trans, since the cost if the shop + diff will probably add up to about the same as a used trans (saw one for about $680 not too long ago, is that a reasonably price to expect for one when I find one?) Plus since the synchro on second is effed, and 5th and 1st synchros are on their way out, its probably the best option. It will really finish up this car (although they're never finished are they )
Thanks again for all of the help guys, I'll be sure to post about what ends up happening.

 

[Mauispyder]

Is there a weak point? Well here is my opinion. Most guy i know do no maintenance to the trans. They might change fluid but thats it. Trans items wear like any other. I have show many guys severe issues with bearing play when i changed a clutch for them. None made any repairs because the trans shifted into gear well. Guess what happened. I check bearing play when i change a clutch. Given the age of these cars i know few units that have under 100k. Now there are definate weak points in the trans but for a mostly stock car this is probably a larger source of faulure for most. Drain the trans. If its shiny or chunky you have work to do. I seriously doubt its the axle

Pauley,
Sorry for my ignorance. Are you referring to the (inexpensive) throw out bearing? I've got a clutch change coming up and I don't want to overlook anything. thanks

 

[pauleyman]

No. Im talking about internal bearings. Seen lots of units with .050 play in the input shaft. Grab the input and see for yourself. If it has a lot of play it should be addressed