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have you checked the speedo cable? when you replaced the speed sensor in the t-case did you make sure that the little gear was attached good and that it lined up ok? and one dumb question is the speed sensor tight and the cable plugged in all the way i had that problem on a ranger i used to have where the speedo wouldn't work at first then after driving for a bit and hitting bumps it would work fine turned out the cable wasn't completely connected at the trans
 
Discussion starter · #22 ·
Brand new connector was installed when the new speed sensor went on. It's on correctly and the problem was happening prior to the speed sensor being replaced. There isn't a speedo "cable" it's all electronic. Bumps have no effect, it all seems to be speed/temp related. Thinking of trying to drain the transfercase and see what happens since it so overfilled.
 
Discussion starter · #24 ·
Okay, so this morning I drained the transfer case. definitely had more fluid in it than it should have. I couldn't get to the "fill" plug to put more fluid in it, but figured it would "fill" from the trannny eventually so wasn't too worried about it. Especially since it's chain drive, it's not like there are clutches that need constant lubrication. Anyways, Speedo works great and the clunking noise went away.

Bonus, just sold it!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
 
sweet glad it worked out for you and noe that i think about it the speedo sensor is probably like an abs sensor with a reluctor ring so the excess fluid was probably keeping the sensor from seeing the notches in the ring
 
Discussion starter · #26 ·
It's a gear driven sensor, the faster it spins, the faster the speedo shows. But I think there may have just been too much fluid on the worm gear driving the speed sensor gear and it was slipping or something. Once I got enough speed going, it flung enough fluid off it would start working. Who knows. It was working great this morning after draining the transfer case, wasn't bouncing or anything like it was before.
 
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