NP205 - Moving Noise

[NVBUYER]

Well I told ya'll I'd report back on the cause of this - I eventually took apart and replaced all the ball bearings, (tapered) roller bearings, loose roller bearing and everything else in between including seals (in the 10 spline NP205 transfer case). Checked for wear and play, (forks and races were fine) to which I concluded the darn case was like new minus a little bit of gear play. I torqued all of the yokes, bolts and all the other goodies to about/near what they were supposed to be and put the transfer case back in. I repacked the double cardan and u-joints and checked my slip-joints. Drivelines checked out, u-joints were fine. Filled the case with some standard 80-90W gear oil and took it for a test drive. Guess what, the noise was still there.

Here's the fun part... When I was installing the t-case for the first (yes there were others but I won't even get into that haha) time I noticed a small rattle when I turned my front driveshaft; a quiet but noticeable metallic noise coming from the left front hub. I didn't think anything of it until I started discussing this whole issue with my mechanic last week. He kept it over night and called me the next day to report back what he had discovered. I should have investigated it when I heard it. The cam inside my Selectro Hubs had broke in half. [See attached picture] The noise was being generated by the sliding gear trying to engage while driving. If I would hit a bump, it would come close enough to put up a vibration through the frame and sounded like it was right underneath the cab. I hate to admit it but I was mistaken. So if you ever hear a noise that sounds like gear grind, check the easy/cheap places first! (Although I had both of the hubs apart 2 other times this winter, they were fine when I had them apart. I didn't think they could break so easily and it still has me stumped how it happened.)

So even though I have a nice and fresh t-case, I could have saved myself a whole heck of a lot of trouble. Thank you all for your help in the pursuit of this mysterious noise, and a special thanks to jbclassix for his detailed NP205 rebuild info found here [http://67-72chevytrucks.com/vboard/s...d.php?t=469726]. I really appreciate it. Hopefully someone down the line will be able to use this as a starting point.