Replaced transfer case actuator gear. Seated the gear firmly, put the motor back on tight, put the mounting bracket back on tight. After the first test drive, there is an audible clicking noise while driving forward that was not present there before. Pretty substantial sounding like something isnt lined up. Anyone have any ideas what might be causing that? Did it not spline right? Does the mounting bracket really have to be super exactly aligned when you reinstall? Any help greatly appreciated. Thank you.
Sounds like you need to back track go over your work.
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Retraced my steps, I had run the wiring harness under the rear drive shaft and too close to the transfer case causing it to clack. Rerouted over the driveshaft clacking gone. Rookie mistake I guess!
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