Bought my 1992 jeep yj, 4.0, 5 speed manual in january. 4 wd problems ever since, no 4 wd.. Vacuum system checked out ok.
Pulled transfer case, bad forks and bearings. Rebuilt the case.
4wd worked for about 1/8 mile on dirt road then very loud gear nashing noise and jeep locked up, would not move. Put in 2 wd and drove 10 miles back home with no problems. Unhooked linkage and put in 4wd from lever underneath, moved a foot with same noise.

Removed transfer case again and had it inspected at jeep shop, all in good condition. Put back in and removed front axles, looks ok. Removed front dana 30 carriage, ring and pinion gears loo good. Spider gears a little warn. All moves freely.
Checked gear ratio, 3.07
Trans does grind a little changing some gears but runs fine otherwise.

Going to install asussie front locker while apart.
Could hubs cause a problem, maybe different gear ratio in rear
Differential ?

What else could be wrong ?

Don’t know what bolt to remove next, not many things left.