So I have been fighting this noise that sounds like a clank against one of the drive shafts that at first I thought was the rear differential with the ARB air locker chewing up my air line. When I start to take out the drive shafts both ends are barely finger tight, but I was still worried, so I took the rear differential out and confirmed the air line was still intact. I put it all back together and got the drive shafts both ends tight and the noise is still there.
Next, I try and isolate the noise by taking out the front drive shafts but the noise was still there. Next, put the front back in and took out the rear shaft. When shifting the transfer case to low, I hear the same clanking sound I have been hearing but the truck is off and not moving. When I test drive the truck this time, the noise is gone. But since I had the same clanking noise when I shifted the transfer case into low, it is now making me think I screwed something up when I rebuilt the transfer case with the low range gears and converted it to part-time. I also saw a small drip coming from the front output shaft area of the transfer case when I was putting the front drive shafts back in.
The thought that I might have to pull the transfer case again is just devastating. I guess I am just going to sleep on it for a night or two and figure out what to do next.