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what are the specs of your truck? dual cases? lift? can you make a video of the noise? picture of truck? is your driveshaft out of phase? is your pinion angle correct based on type of driveshaft? toyota gear driven trans/transfer case can get noisey/rattle if these things aren't correct. there is no such thing as a brand new trans/transfer case for that truck as far as I know . did you have it rebuilt? by who?
every lifted toyota truck will benefit from a cv rear driveshaft. with your standard driveshaft, the pinion should not be pointed up to the transfer case. if it is, it would definitely cause gear chatter and would be louder at different rpms and gears. I'm not saying it's the issue but it's a place to start. putting a cv shaft in my single cased 4runner made a big difference
most mini trucks already have a cv front shaft but yes, both front and rear should be cv. you should remove the shims and test drive again possibly even reverse them to gain proper geometry. these links explain it well http://www.4xshaft.com/ and http://www.4crawler.com/4x4/CheapTricks/Driveline-101.shtml and yes, you should complete your suspension mods before having your cv shafts made/modified. here's a drawing of how your current shaft angle should be. if you point the pinion up with the shaft shown in the first drawing it will vibrate /rattle the transfer case. the more severe the angle, the worse it will be. once you have a rear cv shaft, you will want to point the pinion up to the transfer case as in the second drawing
I haven't had a chance to really read all this, but if you want to add a cv and keep it Toyota parts, i would find a ifs shaft and have it clearanced and put on your existing shaft. You will have to make sure the cv will bolt to your tcase flange. I run tripple drilled flanges so i can use non cv, 4cyl cv or v6 cv, as they all have different patterns
and Ding, I do think I'll go that route in the end - no CV up front and clearanced CV in the rear.Thanks again for your helpCB
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