98 ZR2 4X4 front end noise,fuse blows

[darkarlaw]

My son has a 98 ZR2 auto, started with right front end noise, if he puts it in 4wd the noise goes away. He had the right front axel shaft relaced but it still makes noise. Now it blows the 4X4 fuse when he tries and engages the 4wd. Is it the transfer case controller issue? Anyone had this issue?

[rlith]

Originally Posted by darkarlaw

My son has a 98 ZR2 auto, started with right front end noise, if he puts it in 4wd the noise goes away. He had the right front axel shaft relaced but it still makes noise. Now it blows the 4X4 fuse when he tries and engages the 4wd. Is it the transfer case controller issue? Anyone had this issue?

More likely a short in the encoder motor.

[darkarlaw]

Originally Posted by rlith

More likely a short in the encoder motor.

Thanks for the info, where is the encoder motor located,we will check it out.

[rlith]

Originally Posted by darkarlaw

Thanks for the info, where is the encoder motor located,we will check it out.

Attached to the side of the transfer case.

[wubjo2]

Originally Posted by darkarlaw

My son has a 98 ZR2 auto, started with right front end noise, if he puts it in 4wd the noise goes away. He had the right front axel shaft relaced but it still makes noise. Now it blows the 4X4 fuse when he tries and engages the 4wd. Is it the transfer case controller issue? Anyone had this issue?

BEWARE if this is a front end growl! I've experienced this intermitantly especially while coasting (vacuum increases to pull actuator), turned out to be a faulty VACUUM SWITCH on transfer case giving partial vacuum to actuator under battery tray trying to engage front differential while in 2wd. Result, growl from clutch sleeve (riding on clutch shaft in reverse rotation with planitary gears while in 2wd) trying engage clutch gear (to power right axle) rotating in forward direction. Growl caused by opposing rotation of gears with diasasterous results to gears involved!! IMMEDIATELY check that vacuum actuator is not pulling cable when in 2wd (you cannot see this except thru small opening behind headlight area with good flashlight or run vehicle from removed battery by jumper cables with battery tray removed), if it is pulling the cable disconnect it by releasing straight portion of spring clip (pull outward from its slot in actuator shaft) and replace vacuum switch ($35+ from dealer). You might check how much damage to the gears has already taken place draining diff. oil and check for metal shavings, oil should be changed anyway just to avoid getting possible shavings into other parts and causing problems. I hope this spares you what I have had to suffer with this faulty design flaw - no engeneer should placed main driveline parts in vulnerable link to weak switching device without a backup cut-out device to prevent catastrophic failure of components.

[panamared]

Originally Posted by wubjo2

BEWARE if this is a front end growl! I've experienced this intermitantly especially while coasting (vacuum increases to pull actuator), turned out to be a faulty VACUUM SWITCH on transfer case giving partial vacuum to actuator under battery tray trying to engage front differential while in 2wd. Result, growl from clutch sleeve (riding on clutch shaft in reverse rotation with planitary gears while in 2wd) trying engage clutch gear (to power right axle) rotating in forward direction. Growl caused by opposing rotation of gears with diasasterous results to gears involved!! IMMEDIATELY check that vacuum actuator is not pulling cable when in 2wd (you cannot see this except thru small opening behind headlight area with good flashlight or run vehicle from removed battery by jumper cables with battery tray removed), if it is pulling the cable disconnect it by releasing straight portion of spring clip (pull outward from its slot in actuator shaft) and replace vacuum switch ($35+ from dealer). You might check how much damage to the gears has already taken place draining diff. oil and check for metal shavings, oil should be changed anyway just to avoid getting possible shavings into other parts and causing problems. I hope this spares you what I have had to suffer with this faulty design flaw - no engeneer should placed main driveline parts in vulnerable link to weak switching device without a backup cut-out device to prevent catastrophic failure of components.

This sounds exactly like what my 01' ZR-2 is doing but I have the electonic shifting transfer case. I poster a question further down about intermitant front driveline growling. What would be causing that on mine? I'm assuming no vacuum switches on mine. I've had mine to several shops and nobody can figure it out.