Drivetrain grinding/scraping noise

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amurp15

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Hey pals. I’m having an issue with my truck that I’m trying to self diagnose but I can’t figure it and it’s driving me crazy. Hoping someone had the same/similar issue in the past that can point me in the right direction. Thanks in advance for the help.

Context: 2016 2500 PW. 6.4L v8, 66RFE, manual transfer case, 4.10 axles. 200k miles, transmission rebuilt at 170k, sold to me at 180k, noticed this issue at around 195k. Service history unknown.

Symptoms: Hearing a low-pitched metal-on-metal scraping noise when cruising, coasting, or braking. This noise is loudest/most apparent between 15-40 mph but can be heard at all speeds. It seems to go away or at least get significantly more quiet when accelerating. Doesn’t matter what gear the truck is in, or if I’m coasting in neutral.

When it first started happening, I chalked it up as road noise from the tires, since it’s fluctuating, but the more I listened, the more I determined that the noise was not matching up with the tire speed.

Yesterday, I put the truck up on jack stands and spun the tires by hand, nothing. But putting the truck in drive and letting the engine power spin the rear wheels, I could replicate the noise.

Based on everything I just said, I can say with some confidence that the noise is coming from one of these places: transmission output shaft (not likely since transmission is mated to the transfer case, but still possible since the rebuild could have been done incorrectly), transfer case (changed fluid in Jan. Had oil analyzed and found no problems…still not ruling it out completely though), or rear differential input shaft bearing.

I can’t exactly pinpoint the noise just listening to it, and the driveshaft has no play in it that I can feel just by shaking it. My next step is a transmission oil change, and a rear diff oil change (waiting on parts and a free weekend).

If any of you have had any issues with the parts I stated above, please share. I’ve found knowledge of common issues to be the most helpful in attempting to diagnose things like this. Thanks for your help.
 
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bigdodge

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The center axle disconnect can get water in it and start shorting causing it to lightly engage. Unplug the disco on the back side of your front axle on the passenger side and see if it goes away.
 

star_deceiver

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Worn transfer case chain and internals. Chain rubbing on the housing. Drain the fluid and see what kind of shavings are in there.
 

bigdodge

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Yes. That's the part. If you do have to replace it look for the aam (American axle manufacturing) part. It's the same and half the price of a Mopar one.
 
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amurp15

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1742607722557.png
Here's my transfer case oil analysis...didn't think much of the extra metals since they seemed above average, but not too high. But now that I'm having this issue, I'm thinking more and more that @star_deceiver is right. Is there an easy way to crack open the transfer case and poke around or is it a fairly labor intense job?
 

star_deceiver

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My coworker is currently doing a rebuild of his NP273 from his 2011 Cummins… on deceleration, the chain rubs the housing.IMG_4112.jpeg
 
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amurp15

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wow...that sucks if that's what prompted the rebuild. I'm curious how common this is...

I wonder if the cause is a loose chain. You could replace it, clean up the housing, put it back together, and get another 100k miles out of it. The other cause would be the shaft/bearing tolerance opening up allowing for axial/radial play. In that case, the full rebuild is needed. If you could get some more info from your coworker, I'd really appreciate it.
 
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