i just got a 2004 3500 quad cab, once getting it home i had some problems using the 4X4, it would grind and finaly engage, i jacked it up and drained the fluid out of the transfer case, it was very matalic and several pieces of metal came out. My question is would you just try to rebuild it, or just buy a rebuilt/ new one. Also who to get kit and parts from.. i have not removed yet so not sure what is all messed up inside....

 

uh really??

 

Mines doing the same on. A 07. If I slow down to 10 mph it shifts fine. Might be tire size problem for me anyway. My front yoke also has play in it. Not sure what that's from

 

Not sure what's that's from as I d not see any way to adjust it. As for rebuild or replace. If your doing work id get a reman. Mainly due to warranty ect.

 

What did the pieces of metal look like?

Probably too late but did you take pics of the pieces?

 

shooting back to my delima on mine im hoping someone can shine some light on the subject.

How much vertical play is acceptable in the transfercause output? going through the manual for my 04 its looking like its not tapered so the front output shaft is just inside of a bearing then snap rings hold it in place? can anyone confirm that?