Ok fellers I have been having an issue and decided to break down and see what the good folks at CF has to say. Here is the most detailed way I can put this issue:
Jeep was having a grinding popping type sound with it in 4wd when turning. so I brought it in the garage and jacked it up and put it on 4 jackstands and had the wife "drive" it while I looked at the rotating assebly. When the axles would chatter was when it was turned to the left and it acted like it would of it it had a locker in it. the inside tire would roll with minmal chatter and the outer tire would be almost stopped and would jump. It only does this while in 4wd.
I have checked the front ujoints and the front wheel bearing assembly. I removed the front cover and rolled the diff gears around and looked for any shavings or broken teeth and have none.
I have removed the axle shafts and inspected the splines on it as well. I have no clue what this is and its driving me crazy.
Could the gears backlash if over or under cause a chatter that would act like that?

 

How are the u joints in the axle shafts? Does the steering wheel jump around when turning?

 

The Ujoints are in good shape. No play or grinding in them and the steering wheel did have a bit of jump when it was on the jackstands when it was to full lock.

 

Could be a binding u joint causing the problem even though there is no play or grinding. Did they move freely in all directions?

 

yep. they feel like they are new. I have them out now but when it was assembled I looked at each joint while it was driving in 4wd on the stands and they looked to not be binding. I thought it was the transfer case because of the clunk sound the other day and removed the front plate of the Tcase to check the chain, it was needing a replacement so i did that while it was in the air. This problem is making me crazier.

 

Driving on hard surface in 4wd ?

 

No I was driving on snow when it started. It has gotten progressively worse though.

 

Im gonna vote u joint in axle binding when loads on it 1996 never greased ?

 

Greased every oil change.

 

well guys I removed the U joints to inspect them they were good. With all the agervation I went through to remove them I threw in a new set. Still having a binding issue with the ole jeep. I am at a loss now. The only thing I can think of is the gear set now. Any more ideas?

 

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Is the jeep stock or what? Spider gears look good?...sounds weird.

 

yeah the ole jeep is stock. I was planning on putting a lift and new tires on it when I had gotten back from the desert but until i get this fixed I am holding off on that. I will take a pic of the gears. I think they look good. I see no chipped teeth on it and there was no bug amount of shavings in the gear oil when I changed it.