Well, come to find out, it isn't the transfer case and is indeed the front end. I pulled the front cover and to no surprise comes muddy thin water with very little gear oil. Locked the 4wd in wile motor running killed the motor put it in neutral crawled in front of the jeep rocked it back and forth and watched bind up and pop. I'll try and get a video of it.
It is binding when I lock the front end. The ring or pinion don't want to turn both side gears and spider gears turn? Every thing turns just fine except the ring and pinion. That's all I know about it. Never have tore in to differentials before
Front drive shaft isn't in. And i don't think its the front end neither cause I unplugged the actuator? That locks it in and it still pops. It will move ~2 ft before it binds up then pops and will go another 2 ft.
This part. Front drive shaft isn't in. Front drive shaft actually is in? Changes everything.
There is no front drive shaft in. Its laying in my garage in two pieces. Its the front end that's locking and popping. It only does it when the two front tires are locked together. IIvtaken the actuator off and used my fingers to lock and unlock it. So I know its only when both wheels are locked together.