My transfer case has developed a rattle when the hubs are engaged and not in low range. I pulled the inspection cover and noticed the sliding gear that engages low range was real loose. I kind of shrugged it off and refilled the case with fresh gear lube. There wasn't any metal in the old oil, just some evidence of water intrusion which I expected. After doing a little browseing I have come to a half baked conclusion that half of the shifting fork is missing. Has anyone had this happen to them? I haven't had a chance to go back and search for the piece that may have come off yet but tomorrow hasn't been touched yet.

 

YEP! it is a half baked conclusion alright. The shifter fork is in one piece and all where it is supposed to be.

HOWEVER, the reardrive clutch ring may need replacing sooner than I like. It has a lot of slop and is causing the rattle when the front hubs are locked and in two wheel drive. That stupid one lever design needs to go away. Has anyone converted to a two lever design on a Dodge? I could use some help with this fellow.