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Transfer Case Chain - Testing:
The chain typically lasts between 60k and 90k miles.
It stretches with use, and can get bad enough to skip over a tooth on the sprockets. Loud noise difficult to locate.
The only non-invasive test for the chain is to shift to HL or L and measure how much slack there is between rotating the front and rear output shafts. One will need to be disconnected so that it can be moved freely. If you can make the chain slap the case, or if there is more than a little slack movement, consider changing out the chain and sprockets.
The pump pickup tube (and O-ring) often need to be replaced as well. Also, the fork pads should be checked.
Short plug: http://www.bluehummer.com/trcarekit.html
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