Well the transfer case is in need of some repairs. I've always had the clunk between drive and reverse but it has gotten worse. The u-joints were changed a year ago and a they are still good. The case is leaking from the front output seal and the bottom cover. It looks like the previous owner(s) had the case apart once, lots of permatex gasket sealant on every part. I read the mainshaft spline wear update in the tech service section. Maybe it's time to consider this? I also found some play in the rear diff with a metallic clunk when turning the drive shaft by hand left and right. Normal or do I have another problem? The front shaft has alittle play to, not as much and no odd sounds.
So this brings up questions on removing the case. I've read through some postings and maybe I missed it, but isn't there a way to remove it without dropping the exhaust? I hate battling with those damn manifold bolts. It looks like it will come out if I remove the support bracket on the right side of the frame. The ZF transmission portion of the bulletin says the to refer to section 44 of the repair manual. What page, the govenor housing part? Does the transmission need to be removed for that repair? It's all kinda vague, can anyone help make it clearer?
So this brings up questions on removing the case. I've read through some postings and maybe I missed it, but isn't there a way to remove it without dropping the exhaust? I hate battling with those damn manifold bolts. It looks like it will come out if I remove the support bracket on the right side of the frame. The ZF transmission portion of the bulletin says the to refer to section 44 of the repair manual. What page, the govenor housing part? Does the transmission need to be removed for that repair? It's all kinda vague, can anyone help make it clearer?
