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Posted by DSM_ThuNDeR, Aug 28, 2008
Drivetrain Tech - 4G63 transmission, clutch, flywheel, driveshaft, gears, differentials, transfer case, shifter, etc.
Well, since the car is up on jack stands, disconnect the transfer case (5-bolts) and lay it on the ground attached to the driveshaft. Then you can easily rule it in or out for damage by doing the same thing as you did above. Then you are left with the transmission only. If the problems go away, then you know you need to replace the transfer case. Also, since it is disconnected, you can drain it and see what comes out of it.
ok... be back in 20 mins to post the conclusion!
My bet is its your transfer case.
While you are under there, drain the rear differential and see how much gear oil comes out, and the condition of the oil.
When you come to the time to replace the gear oil in your transfer case and your rear differential, go with Redline Heavyweight Shock Proof Gear Oil (RED) -- it has been a proven favorite in these cars to handle the shockload without degrading over time and abuse.
Has your car been to a dealership to have the transfer case recall done to it? The transfer cases were a recallable item for a while, because if it failed prematurely, it would lock up the transfer case, and pretty much put you in a really sticky situation -- especially if you were doing freeway speeds when it locks up.
The fluid color may or may not help. Mine wasn't silver, but was not functioning correctly.
There is also a plate on the top side I beleive that you can inspect the gears to check for damgage or chipping.
part #3 http://www.thedsmgraveyard.com/v/vspfiles/photos/NMD758205-2.gif
Found this while looking for the image, could be useful as well
YouTube - AWD DSM Transfer Case Check