Well after a great year with few problems I finally did it. I went wheelin again yesterday, decided to take the my sport to a new area, I ended up caving in my rocker panels (on a high center). The sportage amazed me again on the places it will go. anyways I didn't have to use the 4x4 very much, but after I left the playground I began to hear a pop every now and again and a slight slip, when I take off. I thought it was a u-joint. got it home done a quick clean up and got under it to check the u-joints.. Well it isn't a u-joint.I placed it on jack stand and check the rear end. Not the rear end either (I don't think).. started it up and placed it in gear, released the clutch and pop. After several more attempts another pop. A buddy (not to smart) climbed under the truck and advised that the pop was in the transfer case. He says it is grinding as well. Placed it in low lock (front hubs unlocked) and the pop was more consistant. What Have I done.. what is making the grind and popping sound.. Any ideals and cures.. Maybe the drive chain????? Maybe a bearing????? HELP...lol... I thank anyone that may have my answer.. O and is there a easy way to fix the rocker panels..lol...

no easy way to fix the rockers. i suggest amputation and fill the gap with some 4x4x3/16" wall tube welded to the frame with 2x2x3/16" wall tube legs.

as for the popping- did you make absolutely certain your front drive was disconnected in every possible way- t-case not engaged, front hubs not engaged, etc? next thing- are you absolutely certain it's not a blown u-joint? how about a rock or other debris between either the wheel and drum inside the drum? and more- how about the t-case crossmember? is it dinged? is the t-case torquing into it? is the bushing under the passenger side still keeping the t-case from torquing too far? are your other suspension bushings, bolts and nuts still intact? how about shocks? bushings still intact? still functioning properly? lastly- check motor and tranny mounts for wear and tear. maybe also check fan and shroud clearance. if there is nothing wrong with any of this, then it is possible but not very likely, that it could be something wrong with your t-case chain. if you're in 2wd, though, the chain is not even engaged, so, that should rule it out. unless something is worn or broken inside the case allowing the 4wd to almost be engaged when in 2wd and almost not be engaged in 4wd- like a shift fork.

I willing to bet money that it's a hub. MIne did the same crap. Happened to me again two weeks ago with the Warn manuals... (?) The left hub on my Sportage is blown again...

Dave, Thanks for the input.. I have checked under the sportage again. The t-case is dis-engaged, as well as the front hubs. I've re-inspected the u-joints, No problems found. The t-case is secured properly. Nothing is found in the drums either. After hearing and listening to the pop for a few days now I have decided it is to far back for it to be coming from the t-case.
When I take off from a stop in first gear the sportage slips as if the transmission is starting to slip. Then lets out a pop. And now as of lately I have noticed if I'm turning the pop will continue until the vehicle to going straight again. I have only heard it pop once or twice other than when I am taking off. I have taken of hard several times. The vehicle does not pop when you really get down on it and is still pulling positive traction. I'm going to assume my next step is to inspect the R&P in the rear end.

Dave, Thanks for the input.. I have checked under the sportage again. The t-case is dis-engaged, as well as the front hubs. I've re-inspected the u-joints, No problems found. The t-case is secured properly. Nothing is found in the drums either. After hearing and listening to the pop for a few days now I have decided it is to far back for it to be coming from the t-case.
When I take off from a stop in first gear the sportage slips as if the transmission is starting to slip. Then lets out a pop. And now as of lately I have noticed if I'm turning the pop will continue until the vehicle to going straight again. I have only heard it pop once or twice other than when I am taking off. I have taken of hard several times. The vehicle does not pop when you really get down on it and is still pulling positive traction. I'm going to assume my next step is to inspect the R&P in the rear end.

Dave, Thanks for the input.. I have checked under the sportage again. The t-case is dis-engaged, as well as the front hubs. I've re-inspected the u-joints, No problems found. The t-case is secured properly. Nothing is found in the drums either. After hearing and listening to the pop for a few days now I have decided it is to far back for it to be coming from the t-case.
When I take off from a stop in first gear the sportage slips as if the transmission is starting to slip. Then lets out a pop. And now as of lately I have noticed if I'm turning the pop will continue until the vehicle to going straight again. I have only heard it pop once or twice other than when I am taking off. I have taken of hard several times. The vehicle does not pop when you really get down on it and is still pulling positive traction. I'm going to assume my next step is to inspect the R&P in the rear end.

hey, triple-poster, one last thing- it sounds to me like a side or spider gear tooth is skipping or you've sheared some rear axle shaft splines. but it could be brake shoes sticking, broken and catching, etc. <img src="/forums/images/graemlins/zombie.gif" alt="" />

I had a pop like that for some time. 1st it was the rear schocks that had bent and were popping and then it was the nuts that hold the body lift, guess they came lose.

Problem found....
Well I finally got time to pull the rear end apart. When I pulled the Pumpkin out and inspected it, I found that the pin going through the spider gears is chewed up pretty bad. The bolt that hold the pin in place is gone. The pin has worked around and enlarged the holes about 1/8 of an inch. The ring, pinion and spider gears are still fine. The carrier and pin are shot..
I called around a couple of junk yards right at closing time, each one I called didn't know if they have one or not <img src="/forums/images/graemlins/scared.gif" alt="" />.. If I'm not mistaken it's going to be easier to just replace the whole pumpkin.?. Does any one know of some place anywhere close to Kentucky that has one, or does anyone have one for sale?
Thats for the help guys and gals..

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