I have a '74 Scout II w/AMC 258. I recently changed out the xfer case from the single speed chain driven to the Dana 20 gear driven. I also did the twin stick conversion and the lower gear conversion (bronco gear) on the dana 20. I've been driving to work and school the last couple weeks and have not noticed any problems. This weekend I decided to take the wife and rig out to do some 4 wheeling/prospecting. I usually have the radio on kind of loud as the tires and road noise drown everything out. Anyway, we got out into the country where radio is gone and so I turned the radio off. It was then that I noticed a slight, dull, not very noticable ringing noise (for lack of a better word), sort of like the noise you get with hitting hardened steel with hardened steel. It was not very loud. I did notice that when I let my foot of the gas and coasted it was a little louder, this was also the same when winding out in a gear (hitting the higher rpm range of the 4 gears in the 4 speed tranny). I know I did not assemble anything wrong as I triple checked the assembly, clearances, runout, backlash, etc. Everything was tight, no slop. It has plenty of fluid and beside the slight noise works great. Just don't want the xfer case to explode Any thoughts on what could be making the noise, and do you think it is a problem? Could it be gear chatter? How about the twin stick assembly (sticks are not loose but tight - can't wiggle from inside the cab)? As I mentioned, I have never had a gear driven xfer case, could the slight noise be normal operation? Thanks again.

Oh, forgot to mention that all the gears were new (as were the idle shaft, thrust washers, and bearings, races, etc.) except for the bronco gear - was used but in excellent condition.

Sometimes the gears whine at higher speeds, could that be what you were hearing?

I had an early D20 from a Jeep behind my 727 for a short while - and quickly remembered about the oddball tooth pitch on the early units.. it was a VERY noticeable whine at anything above a crawl, and it only got worse the faster you went..

The whine is not loud at all. Seems it is only heard when at high speeds and coasting or when the transmission is winding out in which ever gear it is in. I've read a few articles on the web that mentioned that the new gear faced should have been wire brushed to prevent whining - I didn't know about this or do it. Others mentioned whining/noise being a factor when the gears are meshing. Anyway, I hope its no big deal - hate to see my creation implode :mad3:

Mine started makeing that noise about two years ago, at first I thought of trouble and waited for it to explode (I have spare everything anyways) and waited and waited but it doesnt seem to do any damage (that Ive noticed) and ive put 50+ thousand miles since then and never had a prob :confused:
Although it is a scout so be prepared :flipoff2:

If it's just the noise bothering you and not a sign of trouble. Try some synthetic oil. Redline recommends their MT-50 for the Dana 20/300 and manual transmissions.