3rd gen Xfer output flange wear
I have a '98 4Runner with 185K miles. 5 speed, v6, stock. I noticed a part-throttle vibration (transitional vibration between power on and power off - felt like a bad u-joint) about 10K miles ago.
I found that the rear transfer case output flange nut was loose. I tightened and restaked it, and all was well. 10K miles later, it was loose again.
This time I noticed that the splines are worn to the point where you can rotate the flange (rotational play) while on mounted the shaft. What I cannot determine is if the shaft in the xfer case is worn, or if it's the flange, or both.
Tightening the nut doesn't really solve the problem (long term). Has anyone seen this before? I presume when you slide on the flange, it should have zero rotational play, right?
See attached pix - the xfer output shaft seems to show wear on the splines (this'd be the expensive part).
Thanks - Steve
Colo Springs, CO