Transfer Case Problems

[pcasciola]

I think the transfer case in my 2000 Grand Cherokee is shot. It's the Selec-Trac NP242/NV242. I hear a constant metal on metal sound when it's in 2WD, almost as if the chain is rubbing on the case, and if I try to put it in 4WD it sounds like the whole thing is going to fall out. I've changed the oil to see if it would help and it didn't, and now I am trying to remove the driveshaft to make sure it's just the transfer case before I go out and find a replacement. The CV at the differential came out easily, but the CV by the transfer case will not budge. I was thinking of heating it up with a torch, but I'm afraid the metal on the CV will expand more than the yoke and make it even tighter, or I might melt the rubber boot that goes into the CV. Any other ideas for breaking this thing loose without destroying the driveshaft?

[pcasciola]

Turns out the rear CV of the front driveshaft was bad and not the transfer case. I'm guessing the heat generated from that CV spinning and grinding is what caused it to expand and freeze in the yoke. A big hammer and a cold chisel finally broke it loose.

Just an FYI for anyone that runs into this problem, there is a groove on the rear CV that you can get a chisel into to help break it loose, hitting it at an angle from the rear of the vehicle.