So I installed my tranny & tcase today. No driveshafts, yet.

Tranny in neutral, tcase in 2 high.

When turning the rear yoke by hand, there is a slight click or catch when you first start to turn the yoke. It happens forward or reverse, but only when you first turn the yoke. Otherwise, it turns smootly.

Can anyone tell me what might be wrong? Does it need fixed? Will it grenade at the worst possible time, and leave me stranded in BFE in a snowstorm? Can it be fixed by just removing the rear output? I don't really have the time, or want to spend the money rebuilding my D20. I'd like to bandaid this if possible, and hold out for a real tcase upgrade in the future. I'd really like to fix this without taking the tcase back out.

Have you thought about pulling the inspection plate and having a look inside while turning it?

Other than remove & reinstall my tcase, I've never done more than change the oil. Its one of the last parts of my truck that I've never even opened up. I'll try that tomorrow, and see what I can.

It feels like a little slop with the tcase in 2 or 4 high. And it feels more like a catch or click in 2 or 4 low. It doesn't do it in neutral, and the front yoke doesn't do it.

Hopefully someone familiar with the gears can help. I know it's not as easy in your neck of the woods, but D20 cases are pretty cheap to just buy another to swap in.

Does it actually click or does it feel like excessive backlash (play between a set of gears) like when a diff is setup too loose?

I took a closer look at it and it does feel more like slop than a click. In low gear, the slop is more obvious and feels more like a click. It only happens on the rear output shaft and only with the tcase with the rear engaged.

I decided to just reinstall everything and live with it for a while. I've arranged to get a rebuild D20, but its going to take a month or more. I think my junk will hold together, till I can swap it out. I wanted to hold out and scrap the D20 for an Atlas and 4R70W, but that is at least a year or two away.

Everything is together, and I'm going to fire it up today.

You'll probably be fine, if it's just slop it should be fine as long as its not really loose

Drove it today, and it drives fine. I'm sure its on a slow road to failing, but it will last till I can get a rebuilt one. I don't have any thing planned except hunting season in early November, so it won't get pushed hard. Hunting season could be rough, depending on the weather, but I think it will last. Maybe I can get it swapped by then, but I don't know.