Popping noise while driving in every gear.... Someone help!!

[wastedvocation]

I have a 90 wrangler 2.5 ax5 trans, and i keep hearing this popping noise when i start to drive and while im driving in every gear 2h 4h 4l... all of them. I took the trans and transfer case out and took them all apart. i found some gears that need to be replaced like someone ran 4 low like half way in gear and stripped most of the teeth, and in the trans one of the teeth on the gears was chipped but nothing enough to make it pop like it does. when it pops i lose some foreward momentum but only for a split second.... please someone help.

 

[SteelHeadz]

I would check the rear differential.

 

[Saddle Tramp]

X 2 on the rear end. I bet your bearings are toast and it is only a matter of time now. Pull the case cover off, if there is any metal in the fluid or in the bottom of the case you’re done.

 

[wastedvocation]

That would be just my luck pulling everything apart down to the gears and having it be the rear diff..... thanks ill get to it tonight

 

[wastedvocation]

alright i took off the case and inspected everything that i could. for the life of me i cant find anything that looks broken or really worn. i took some pictures to see if my definition of too worn isnt too far off. From what i saw when i drained the fluid i didnt see any metal or anything like that.

 

[Saddle Tramp]

No metal in the oil?

 

[wastedvocation]

none

 

[SteelHeadz]

MMMmm, that answers that. From the pics , it looks good. I would double check the pinion gear and pinion endplay before you put it back together.. If those 2 checks out good, i'd move on to the t.case.. Those worn gears you found in the T.case needs to be replaced prior to re-evaluating for the popping noise. Theorethically, with the output torque from the transmission, its possible that the gears are skipping if the gears are that too far worn down.