Have been running the jereel for 3mo, same castor no noise, wouldn't it have started when I put it on? Not all of a sudden making noise outta the blue?The frt Tcase output flange is not turning when the ds is out, but it's turning when the ds is attached. Couldn't this be a bad bearing in the tcase shaft? It's sounds like a bearing scraping noise, I sent my original je reel back and they sent me another one, same thing immediately. That's what makes me doubt its the shaft because like I said the other jereel went 3mos, no noise, seems like it woulda started immediately like the new one

 

Although, I was about to try to adj my castor when my neighbor came up and said lets put it on jackstands, it was doing all kinds of crazy noises when we did that, what you say about the esp makes sense now after thinkin bout it,Damn, goin to the dealer tomorrow and get my jeep.

 

Did you try to drive it in 4WD with the front shaft off? If it's the tcase it should still make noise if it's in 4wd right?

 

I drove it 4wd low and high with th ds in, no noise. Only when in 2hi at 20-30mph and beyond the noise got worse.

 

Damn neighbor, shoulda stayed and did what I thought was wrong anyway and tryed a castor adj. The wheels off the ground in 4hi scared the crap outta me the noises it was makin.

 

I hope you can figure this out, chasing down ghosts has got to suck!

 

Has the slip yoke on the drive shaft been seperated and possibly put back on incorrectly so the ujoints would be out of phase? Check your axle ujoints closely as maybe when your running in 4WD they have some tension on them causing them to be quieter? I still think its in the driveshaft. The more caster I put into mine the louder and earlier the noise and vibration would come in. You might also try pushing up and down on the front pinion where the driveshaft is bolted on and make sure there is no movement. Also there is three grease zerks on the double cardigan end of the shaft(2 ujoints and the ball socket in the middle). Are all of those lubed and in good condition-especially the ball socket? If you need to do some road testing with the shaft removed (diagnosing your problem)you can just un-bolt it at the axle end and securely strap it up to the frame rail. Just be sure not to engage 4WD with it like that. One more thing is to check your control arm bushings closely. I had several sets of mine go bad which will allow the axle to roll forward and backwards slightly.

 

Went to the dealer today. It was tha bearings. They ordered all new bearings, seals, and a few other parts basically to rebuild the Tcase. One of the parts, guy at the counter didn't have the parts list, has a 3-5 day delivery wait, so I'll be jeepless for another week or two, but......They're covering it all under warranty! YeahhhBoyyyeee.
I think the beer I dropped off did the trick. Now I'm wondering if I shoulda dropped off some Jack daniels and Crown , mighta got a Rubi Tcase!LOL

 

You may also try throwing back in your factory drive shaft and see what that does. The factory shaft can run at a steep angle with little or no vibration/noise but will not last very long. If the noise is the same with the factory shaft I would start looking at your ring and pinion as I just noticed you said the noise started after you had them replaced. If the noise dissappears with the factory shaft then you know its in the JE reel shaft and may need to adjust your pinion angle or investigate the shaft further.

 

2nd shaft from je reel, watching it run underneath, smooth as butter. I had absolutely no vibration, all noise like a bad bearing and it was coming from the case not the double carden. Greased the shaft before installing, zerks and the needle fitting. Driveshaft is not gonna turn the bearings in the tcase like that not attached to the frt pinion. All control arm bushings are good and torqued to spec. It was the bearings, thanks for the input though.