Pretty sure we found the problem Saturday. Ran the truck on stands and listened to the trans and tcase through a stethoscope and found the noise emitting from the rear of the tcase. Pulled the tcase, ripped it apart and found the rear output gear badly damage from corrosion. Don’t know how in the world we missed that when we resealed it.
So we ran over to a local bone yard and picked up another 27 spline 205 only to get it home, open it and find it in worse shape… Much worse. It looked like it had been lying in the dirt with the bearing side exposed for decades or it was the tcase off from the Titanic. That tcase is going back today.
Found another 205 on Craigslist for $20 with a broken input shaft Saturday. Figured it would be worth $20 in small parts if it was badly damaged. Got it home and pulled it apart to find it was actually in great shape despite the broken input. So, between my original $25 CL 205 and this latest $20 score we can make 1 good one. Have a bearing and seal kit on order now and will be reassembling next weekend then we’ll see!
