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I sent you a PM to get the conversation started. You'll see a red "1" on the little envelope at the top right corner of the web page. I just noticed you're in NC. There's a good possibility that you can just come to Maryland and pick this thing up. It'll save you the costs of freight and me the...

Hm. I may be able to help with that. I still have my old transfer. It shifted fine but the output bearings were shot for the intermediate shaft. I believe the oil drained clean and without metal bits. PM me if you want to discuss it.

Yumpin' Yiminey bro! Well, you have 3 options- Rebuild it yourself. Pay a commercial truck shop to rebuild it. Buy a replacement. People sell used takeouts all the time but of course that's a gamble. I bought a rebuilt unit still in the shipping can but that fellow retired and sold his...

I've found the transfer case to be a bit grumpy to shift, especially if left sitting for long periods. Squirt some "liquid persuader" on the shift plunger, move the truck forward or backwards a few feet and try again. I know you said the plunger moves but it sounds to me like you're not...