clicking, etc

[trintek]

I did a search, but it doesn't seem to be the u-joints. I have an 84 cherokee 2 door, 5 speed, 2.5l. We just sorted out a load of vacuum problems but am still having a few issues.

2wd: all gears: drives fine, no noise, no slippage, everything is good.
4wd high: very slight clicking noise when climbing a steep grade, some clunking sounds when turning
4wd low: Major clicking noise when climbing a steep grade, major clunking noises when turning, doesnt like to stay in 4 low, i have to hold the lever back.

To take care of the 4 low popping out of gear problem, i am going to remove the center console plastic and see if it holds in place, the console is beat up so it may just not be going all the way back.

As for the clicking, is there a chance that the front axle disengage/engage just isnt properly engaging all the way?

[DaffyXJ]

I had been troubleshooting the clicking noise since Dec. I'm down to chain slap in the T-Case. However because yours includes noise while turning, I'd take a look at the axle ujoints first.
Also possible is the drive shaft. I rebuilt both of mine, yet to no avail, however this is a potential cause.

The low gear popping out is 100 percent linkage. I just pulled all my linkage and rebuit it. had a bad bushing/retainer. Allowed the linkage to bind.

[trintek]

very cool, i am stranded in san antonio for much longer than expected due to the raise in gas prices, so loads of time to do some troubleshooting and rebuilding.

I looked at the axle ujoints, but amazingly enough they seem fine, it mainly does it when doing a sharp turn to either side, and i am starting to chalk it up to the tires rotating at the same speed while traversing different distances... I have only tested it on concrete and firm packed dirt. On even ground it clunks when doing a sharp turn, when going up a grade it clunks when doing a turn more than maybe 25 degrees to either side.

The clicking is only happening on steep grades, etc. I took it into a storm drain and back up the wall, on the way up it clicked. Then i took it up the side of a dirt hill that is roughly 30 feet or so high with a steep grade, it clicked the entire way and clicked very lightly on the even ground until i shifted to 2h or 4h.

I will check the linkage this eve after i remove the console... in my book, the console is pretty much useless anyway as it is a trail rig, i may cut the console at the console box and keep that part, but... it slams into the plastic when i pull it all the way back, so am wondering if the console plastic may be pushing it forward and out of 4l.

edit:
On the plus side, when i get back to my home area, i have a 4wd cherokee, a 4wd international truck, and a 4wd kaiser jeep corps wagoneer looking thing in the junk yard, may be able to re-use some parts from those, or just say to heck with it and start turning this cherokee into a 4 wheel leaf rock crawler