Simple Fix, Turns into Pulling Motor!

[4Motion4g63]

Well I just rememberd how much I love my DSM this week.......



I have been dealing with a little of a phantom "Buzzing"
Noise from my drivetrain in gear under Deceleration, and a wierd knock when i hit the brakes lightly in reverse....
So what did I do.... Swaped transfer, Still there, Changed Rear end, Still there, Changed Drive shaft, STILL there..... Called all the pros I could, they told me it was a combination of anything from balance shaft elimination to clutch chatter and was normal.....
I stopped Looking for anything wrong after that...

I think I figured it out..
Well this week on the way to work, I turned a right hand turn, then the car slipped like the clutch just went out....ummm Damit this happend a few years back in the same way *ironicly the same Corner too* and I figured it WAS a bad clutch! So I saved up to by a bunch of new tranny stuff and a new clutch since I was going to pull it to fix it 9 months after i started collecting parts, I started to tear it down... and when I got to the Drivers side half shaft, the bolts were already out and it was loose aganst the bottom of the motor bay..... So the half shaf was the ISSUE, It slipped out the transfer case and the car Just LIMPED like the clutch was bad.....WTF....

Ok so back to this week, Same corner and the carrier bearing fell off the block again.... NO biggie right... Just get the bolts and put it back and im banging the gears again........ I got the bolts and went to town trying to stab the half shaft back into the transfer, that took 20min to line back up and get in.... And all I need to do is tighten down the two bolts.... WTF its not threading in....Its lined up .... .... spend 20min struggling in a tight space with daylight gone....
take a carefull look at the block and .... the OLD bolt BROKE off into the block.......

I have one glimmer of hope to maybe tap it out, but if you have a AWD you know what area I am trying to work in and how tight it is... Lucky for me the A/C is already gone so it gives me some room.... But If i cant get it to come out ..... I will halfto pull the motor just to get it out.....

So if that happens, Its getting built ....I dont pull motors to tap out a bolt....

 

[e85_4g63]

Damn, I know what bolt (area) your talking about, I'd be pulling the motor, if you can do it without, your the man!

 

[4Motion4g63]

yea its uber lame.....

 

[16vtawd]

If you still have the AC bracket just helicoil it and put a bolt with locktite. Both of the bolts broke flush on my old 1g and this held for me.

 

[nlzn]

It just sucks because there's no space to do anything back there.

I had the same problem with that bolt backing out of the carrier bearing at the block.

Using copious amounts of blue lock-tite seems to be holding for me so far *cross fingers*

 

[->PrOjEcTGS<-]

Have you tried one of these?

With a really short bit it might fit in there...

 

[4Motion4g63]

The right angle is my ONLY hope, I halfto get the bolt OUT to helicoil it...its still in there i dont thing the threads are damaged...