Recently, I’ve been getting some weird grinding noises when driving the vehicle at slow speeds (15-20 mph) particularly if I hit a pothole, or a speed hump, etc. It sounds similar to if two gears are not quite meshed together perfectly, with one spinning, and one not spinning, causing them to grind together.

I recently decided to try putting the transfer case in neutral, then putting the car in the highest gear and see if I can trace any weird noises underneath. Wow, I expecting a little bit of noise, but not nearly this much.

It appears to be coming from the transfer case, but I’m having a hard time deciphering if it’s the transfer case itself, or if it’s the output end of the transmission (output bearing and shaft for example).

I start the video with my foot still on the clutch but around the 10 second mark I release the clutch and you’ll hear the noise. I give a few small touches of gas throughout the video, and you can start to hear the type of gear/grinding noise I experienced while driving.

Has anyone ever seen a transfer case (or 5-speed transmission) make this much noise? For reference, this is a 2007 base model with 152k on the transmission and transfer case. What might cause this? I’ve changed the transfer case and transmission fluid religiously every 30k miles.

I did this same experiment with my wife’s 2008 Alpha, and there was absolutely no noise from the transfer case/output end of the transmission. That said, I was only able to put it in first gear (not 4th), as it’s an automatic, and it will not shift out of first gear with the transfer case in neutral. Ultimately though, it was as quiet as church music, not nearly as ratchety as this video even when I gave the alpha a bit of gas.

My next step is to remove the transfer case, try this again, and see if the noise still occurs from only the transmission. I’ll keep you all informed, but is anyone experienced enough to be able to tell if this is a bad transfer case, or if this sounds more like a failing 5-speed manual?

Any input is greatly appreciated.

Have a great weekend!

https://m.youtube.com/watch?v=FW0ua0gXbr0

 

Check heat shield on pipe near that Area. My gf's 06 h3 rattled loud like that and one day b4 she could take it in to have it looked at on lift noise suddenly stopped. Metal shield broke free and fell out.

 

I checked the heat shield today and it was nice and tight.

I believe I found the source of the problem (or at least part of the problem). There is a considerable amount of play in the output shaft of the transfer case.

The lighting is terrible in this video but you can still see all the side to side/up and down motion.

Bottom Line, I believe the transfer case is toast, or at least in need of a rebuild.

Anyone know if this amount of play is normal? I’m going out on a limb and guessing it’s not, but again, I’ll take any feedback I can get

 

My transfer case output shaft was so wobbly, fluid leaked out all over. I feel like mine had a vibration in addition to a tire vibration, but I also replaced the tires nearly at the same time. I had a replacement transfer case put in for $3k with a warranty at a shop. Way more than I wanted to spend but i had just got the H3 and needed 4x4. I had the transmission and ujoints rebuilt at the same time for $$$.

 

I'd attempt 5o find a parts h3 and pull entire case out of it and swap. Or at least purchase a used one with lower milage at junk yard. That way can just swap and go. Maybe rebuild yours in time then.