About two weeks ago I started to hear a rattle sound, like a rock was stuck in something, only happens when moving, then today I was on a gravel road shifted into 4HI and something began to pop very loud when I accelerated, like it was not getting into gear. Any ideas?

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2006 Liberty Sport 4 X 4

So did it get into gear or did you put it back in 2WD, dosen't sound good.

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Member No: 152595
Susky Bro V The Highlander Terminator, got it Wuggs

Lifted by CRDSTU
265/70/16 STT's on 16x8 Chrome Soft 8's
CDKJ

It went into 4HI just fine and would roll, but in I gave it the gas it started "popping", sound like a binding sound.

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2006 Liberty Sport 4 X 4

could be a number of things but if it only does it in BOTH 4wd high and 4wd low then I would be looking at something on the
front side ,T-case out
is it a 231 or 242?
do the front wheels get power?
are you 100% sure you were not between 2wd and 4wd?
are you 100% sure that you were not just getting good traction?
when was the last time 4wd ,low and high, was used?
when was the last time you changed the oil in the case?

all this could help point to a bad problem or a minor issue

Only tried in 4Hi
Dont know if 231 or 242
Not sure if wheels got power, it sounded like something was going to fall off if I kept going
Last time used was maybe 6 months ago
had everything done 7,000 miles ago.

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2006 Liberty Sport 4 X 4

I had it serviced in Feb. 2008, just crawled under and on the back of the transfer case one of the plugs is missing. Time to get pissed at the dealer.
What should I do now ????? Yes I'm pissed.

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2006 Liberty Sport 4 X 4

Sniper rifle with a good scope should do the trick.

Seriously though, I would go back down to the dealer...although it might be difficult to prove that it was them. I am not sure but I would empty the fluids, put new in and seal it up. Try again and see what happens. That is just me though, I am NOT a mechanic and have no idea what I am talking about.

Get more suggestions though and see what everyone else says.

I would be pissed too. Hopefully it is nothing too serious.

*edit Addition*
TJKJ would be the one I would ask. He seems to have his stuff together...usually. He only takes it apart when doing some mod, lol.

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My Rig:
2008 Jeep Wrangler JKU
OME HD lift
35" tires (thus far)
plus a ton of other things. J.E.E.P.

The same thing happened to my dads SuperDuty,though my so called mother had here boyfriend take the fluid and the plug from his t-case(couldn't prove it though,long story).He drove like that for about 2 months and the noise kept getting louder,he though it was from the front diff,had everything checked and that's when they found the plug gone,they added fluid but the t-case was gone,$650 later all was well after a new t-case was installed.

Most likely the t-case is shot,you can try adding fluid and see but it's most likely toast.You can get the t-case rebuilt or a new t-case for a KJ is $600-$1000(231--242) and is super easy to install.

If I have to should I drive it?

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2006 Liberty Sport 4 X 4

Get the t-case checked first,if it is okay then drive away,if not you should not drive it with a bad t-case.If it breaks while driving it can cause some really bad things to happen(can),like roll the KJ,ruin the driveshafts,ruin the F/R diffs,and can take out the tranny also.Did I mention you could roll or go out of control and cause some major damage?I've seen a Chevy pickup break the t-case while doing 75mph,rolled the pickup(the front driveshaft acted like a poll vault),broke(in pieces) the F/R diffs,broke the tranny,and killed the driver when it rolled into the oncoming traffic and killed the driver of a small car that it hit,landed on it's roof on top of the smaller car.

What are you trying to do....make him piss his pants! Makes me want to go outside and check my t-case. lol

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2002 Jeep KJ Sport 3.7L 4x4

245/75-16 Mastercraft Courser HSX, 16x7 Cragar, 2" OME MD Lift, ARB Bumper
AEM Brute Force Cold Air Intake, Flowmaster Super 44 Muffler

Currently working on: Full service on transmission & bed-lining ARB bumper

viewtopic.php?f=43&t=84650

No,just the cold,hard facts of what can happen--------Get the t-case checked by a certified drivetrain person to determine if the t-case is good or not.

Ya I've been driving the thing since I had it serviced, and when found out about the 4HI popping I drove it home from the hills about 65 miles.. But I'll have it towed somewhere just to be on the safe side. I do have a friend who drives one of those crazy 4X4's that climb "skyscrpaers" , his was even in a mag. about 4yrs ago, to look at it, and ask his opinions as to what to do. Heck he even has a car trailer so I may even save on towing, I live at least 20 miles from either Jeep dealer, so it will get towed.

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2006 Liberty Sport 4 X 4

I called, told the Service Manager that I had the service done if stated that I did, and when I told him what I found he said OOPS !!!!, you need to bring it in ASAP, did not indicate if he was going to pay for it though.

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2006 Liberty Sport 4 X 4

Oops? Wow.

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My Rig:
2008 Jeep Wrangler JKU
OME HD lift
35" tires (thus far)
plus a ton of other things. J.E.E.P.

Dealer says they will pay for the new transfer case

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2006 Liberty Sport 4 X 4

finally! a dealer with a good service department. congratulations!

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2003 limited 3.7L V6
Vader Edition

http://www.cardomain.com/ride/3219059

Well I got the Liberty back yesterday, and they paid for the work, even said it was their fault.

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2006 Liberty Sport 4 X 4