Time to start tracing backward here I think, once you change out that trans.

You have already seen by testing that having the truck in 2wd with the IWEs engaged does not cause the issue so that's out.

If you are certain on the gears being the same then that is out.

Next step is remove the front driveshaft and engage in 4wd. Does the issue crop up? This isolates the transfer case from the front end (front driveshaft, gears and axle). If you still have the issue it is a transfer case or trans issue. If no problem then we have isolated it to the front end somewhere.

Do that and get back to us.

 

It was a used case I bought. So may have been shot already. I'm putting in another used one now. Almost done. Got my fingers crossed

 

I tried that earlier in the week with my rebuilt transfer case. And it drove fine in 4 hi with no shaft.

 

If mine ever has a problem ima have to get you to show me how you get that thing out so fast lol

 

I think I can do it blindfolded now

 

See the problem is you don't have the stickers to make your truck be better than manufacturer spec! The one on the right adds 10hp and more reliability automatically!


And blindfolded you say? Sounds legit

 

Wondering the u-joint now too. If it's not a ratio issue something's got to be binding somewhere. Might not hurt to tiewrap a gopro camera under the truck or something hahaha. I've done that with my car to find a noise.


There is a TSB 06-11-12 affecting 04-06's with the left bracket on the front differential separating. I know you say it's an 07 but depending on the build date, maybe it's affected? Worth a look?

 

it ended up being something with the transfer case. Still dont know what.
I pulled mine rebuilt it. did it. put a used one in and it blew up. put my rebuilt one back in still did it. Then i got another used and its perfect.
Idk. Im glad it works but still curious what happened