Have you checked your front driveshaft "U" joints?
What about the yoke going into your front diff, is it traveling "Centered" as it rotates or is there "Wobble", even the slightest)?
You might have to lift at least one wheel and be out of 4X4, to do this. Does it rotate smoothly or does it feel "Gritty"?
I'm glad my Pal came back over, we were able to test the shaft in question with a Dial-Indicator to measure the End Play of the countershaft----It was.018" (correct tolerance) If the thrust washer had been missing it would have had.080" End Play (slop)
SO, All I had to do was remove the shifter top, Drain the Gear Oil---I did refill with 80W-90 instead of 85W-140----All seems to run well nowI LIKE IT!
I came so close to snatching it all out last night, and tearing back into the tranny---I'm glad I waited!
Heres the "INSTALLED" END PLAY TEST (I take pics of everything now!)
Sunday, January 2nd, 2011 AT 12:47 AM