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Finally a couple of warm days. I tinkered with the truck for a bit today. For a few moments, I was genuinely concerned that I was making an expensive diagnostic mistake. I think I exaggerated the amount of play the rear output shaft has. The truck wasn't making the noise at first, but then...

US6x4/Toby, Yeah, the manual is talking more about "in/out" not "up/down" but that was the closest information I could find. I have up/down/all-around movement, plus leakage. I didn't check in/out movement. Toby, you did an incredible job considering that you were working by feel, without the...

Toby, I've always been decent with engines but not so great with transmissions and transfer cases. The last transmission I had apart, was a 3 speed for an old Ford F-100. But, I digress. I think the bearing is blown. I can't see how the bearing could just fall so grossly out of adjustment...

Hey Toby, I've already done the suggestions in your first paragraph. The rear output shaft can be moved around by hand, and there is a new leak from the rear output shaft seal. It looks like it ate the rear output shaft bearing. I know it can repaired/replaced, but I don't think you can just...

As I am adding to this old thread, you all can tell that I have run my query though the search engine. Nearly all transfer case threads that I can find, are for the 939 series trucks with a smattering of deuce and a half questions. My question is related to the M809 series- Here's what...