Klausc,

Thanks for all your help here.

So when I initially setup up the transfer case, I torqued the nut on the pinion flange to roughly 160 ft-lbs, and my preload was around 18 in-lbs.

Before I took the nut off I tried to get a feel for the torque setting again, but forgot to get a preload reading before removing the nut.

With the help of my son I re-torqued the nut to roughly 154 to 156 ft-lbs, and rechecked the preload. I was right around 8 to 10 in-lbs. Possibly not enough, per your outline, but maybe enough that I can drive the car for a while before I start hearing noises.

I have another transfer case that I will be tearing apart and checking its input splines, and if they are good, then I'll rebuild it and just set it aside waiting for that fateful day when the current transfer case dies.

Until then, I'm driving the snot out of the car and will be enjoying every minute of it!

Matt