Just received my 01 3.0 (124k on the old clock, 0 on the new clock) back from getting a new engine and now there is this clicking sound from the transfer case area. After reading all these posts, i concluded it was the rear output flange that was stripped. Especially when i noticed that there was a 3/8" area that almost appeared to be milled. Guess what...the new one is exactly the same.

Can the chain be slipping inside? As always, the X didnt have this issue going into the shop, just coming out. Just my luck.

Any input would be appreciated. Long time lurker, first time poster.