I dont have any words of wisdom for you Chris - but since we are on the topic of transfer cases I thought this was worth mentioning here:

Transfer case saver, don't leave home without it, DIY and save money!

 

Ok guys i got a chance to climb under there today. I think its the linkage rubbing on the case. I cant seem to get it to stop rubbing. I tried a flat screw driver pushing using the case for leverage but it didn't help. Any ideas?
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Ok the linkage is flipped. Now i have a few more questions. First off when i go from 2 high to Neutral to 4 low with the trans in natural it makes a little bit of a grinding noise. Then back again it makes a little bit of a grinding noise. Is that normal i just cant seem to remember if any of my other truck did that. also im having a hard time getting it out of 4 high any ideas. last but not least when the t-case is in neutral and i put the truck in park i hear a slight grinding noise but only for a split second. Any ideas guys would be greatly appreciated.

 

Need to be stopped to shift from 2 HI to 4 LOW. Splines are moving faster than the gears and are unable to line up right of the bat, thats where the grinding noise comes from. If that makes any sense.

 

It does make sense but the trucks not moving when it does it. Im really starting to wonder what it could be. What makes the gears in a t-case stop spinning when the trans is in N do the slowly spin down or is there some kind of breaking system.

 

Obviously you got an auto. Ok, when you put the t-case in N the output shaft in the transmission starts to spin. When you put it in P, parking pawl tries to engage, then does. Thats where that split-sec noise comes in.

 

That makes sense never heard that befor first truck thats not been a stick. So the slight grinding is ok? What about the loud thud when i shift to and from low?

 

I wouldn't grind gears every time. You'll end up w/ metal shavings, and that will shorten life. Going from hi to low, changing gear ratios. May also want to check fluid level and see if it's dirty.

 

SO you think it would be ok to truck pull with it? I was planning on it this weekend till i found out. It doesnt grind if the trucks off

 

Completely up to you if you want to pull w/ it. Really don't want to say go ahead and end up with you having a wreck.