I have a 96 JGC with a 249 transfer case. Started getting a clunking noise when accelerating or turning sharply. Thought it was a CVS joint, so changed both out and also checked the front driveshaft (CVS type) and it was OK. No luck. Walked next to the car with someone else driving and think the sound is originating at the transfer case. It didn't make the noise when driving without the front driveshaft. Been getting worse. Any help?

Could be the chain slipping. That's what my 231 was doing, although it was a very loud clunking, more like a banging. The mechanic said it was slapping the case so hard that he was surprised the case wasn't cracked.

Could be the chain slipping. That's what my 231 was doing, although it was a very loud clunking, more like a banging. The mechanic said it was slapping the case so hard that he was surprised the case wasn't cracked.

What was the solution? Tightening chain, new chain, rebuilt case or new case altogether? Thanks.

What was the solution? Tightening chain, new chain, rebuilt case or new case altogether? Thanks.
Hi there,
I have the same problem, although it seems like it isn't as bad as yours. I only had the sound (and a hopping feeling) when making tight turns. The dealer I recently bought it from couldn't find it (or at least not reproduce the problem), so I brought it to a certified jeep dealer. It turned out that the transmission fluid was completely burned and there was no friction modifier added to it. Now it has been cleaned and the friction modifier has been added. The problem is still there but they assured me that it would go away after a couple of hundred miles since it takes time for that solution to completely do its job. I have to wait and see. I'll keep you posted if it really was the problem. By the way I have a GJ 2002 (45k mi)

My '96 GC also does that when i put it into 4 wheel, and press the gas, it sometimes sounds like gears grinding together, and i dont know what it is.

What was the solution? Tightening chain, new chain, rebuilt case or new case altogether? Thanks.

I was told that it would be very expensive to replace the chain and whatever else may be worn. I'm trying a used (and as of yet unpaid for) TC, but it seems to have problems also. I'm having a mechanic look at it later today. If it's going to cost a lot to repair, then I'll probably buy a rebuilt one. Transfer Case Express in California and South Carolina has rebuilt 231s for $550 and one year warranty.

I have a 96 JGC with a 249 transfer case. Been getting worse. Any help?

My 95 JGC would do this after it had been run for a while, especially on the interstate--tight turns at slow speeds would make it completely bind up and clunk and hop. Wouldn't do it when it was cool--just when the engine and parts were hot. After trying a few things (replacing the transmission fluid, etc), I had to have the viscous coupler in the transfer case replaced. Certainly not a cheap fix, but I ordered the part from a shop on eBay and it's done fine since then.

VISCOUS COUPLERS ARE ABSOLUTELY HORRIBLE!! They are literally designed to fail. If u drive for more than a few miles on a low tire it can kill them. Don't rotate your tires properly? Dead again! Drive on an offsize spare(Don't lie everyone's done it!) Dead again! Swap those 249's out with something else! I did a 242, u can use 231's too, almost direct swap. You get the added advantage of being able to run in 2WD mode, my 93 5.2 liter now gets 17/21 city /hwy MPG. and I can FEEL the extra power at the pedal. If you've got a bad V.C. in your truck, the AWD is working ALL the time, not JUST when it's supposed to. This puts a strain your entire drivetrain, trannny, front diff. al of it! and wastes gas. Plus evryone looks at u funny when you squeak, squeak , squeak into a parking spot.Check out this link: http://jeephorizons.com/tech/tcase.html

works awesome!!
PS If u do this, GET THE GOOD SNAP RING PLIERS!!
The top bolt that's tuff to get is easy with a 3 inch swivel head ratchet and deep well socket.

Ackie, truly not trying to be mean, but u don't need friction additive in a transfer case. If the dealer told you that, he's guessing or blowing smoke. If u had the problem in your front differential, maybe. But the way viscous couplers(v.c.)work is: they have a silicone type viscous fluid inside of them that is normally liquid, along with plates stacked side by side. When all 4 wheels are turning at the same rate the fluid STAYS liquid. When 1 or more wheels turns at different rate than the others, the plates heat up the fluid and it solidifies and turns like clay,, grabbing those plates and engaging the t-case. When the V.C. goes bad, the fluid STAYS solid and AWD is on all the time. Ask another guy with 4WD to engage his t-case into 4WD and have him turn slow on pavement. It'll shimmy and squeak like crazy. Just like a Grand Cherokee with a bad damn NP249 transfer case. Good Luck 'Bro!