Transfer Case chain and additional components

[miloh]

Hi all,


My 2005 3.0i has had an issue with the ATC500 transfer case for a while where it would kick when switching from P/D/R. From a cold start or too hard of acceleration with a bunch of weight in the trunk it will kick hard or as of recently grind from the TC. I did the actuator gear 1,000 miles ago and got rid of my 4x4 DSC light that would occasionally come on. But now with 173,xxx miles on the odometer, it probably needs to have the chain replaced. Also the front drive shaft has significant rotational play before it engages when spinning the wheels on jacks - not sure if that's normal, but it feels like it's related to a stretched chain. There's approx 35 degrees of play before it feels like the chain is engaged.



I wanted to know what should be done in addition to just the chain in the TC, like what else should I should replace since I'll be in the drive train area. I plan on doing the seals for the TC if they look bad. I think there are U joints or flex discs that are recommended to be replaced too.

Is there anything I need to do with the differentials while I'm down there too? Does my model X have the driveshaft spline issue?

Thanks