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Well, I give up. I can't find one thing that could cause this problem. Everything looks and works as it should. I put everything back together and still have the same problem. I will oil up everything and run it until something breaks. Out of ideas and tired of playing with this issue.
I did check the claw as well as the gears in the transfer case before disassembling of complete front axle. At a loss as to what could be wrong, I am going to reassemble everything and run the tractor on the ground without oil in the transmission, transfer case and front drive. Without oil and top of transmission off I just might be able to see something weird happen and finally get to the real problem.
I did that before pulling everything apart. I am going to reassemble everything and leave the cover off the gear box and move the tractor in 4wd when it binds up I'll stop and try to see if I can isolate where the problem is. I will look at the mechanism in the box that engages the 4wd drive first, I notice that when it binds up I cannot easily pull it out of 4wd. I will try to visually see what is happening in there and the transfer case. I am going to do this without oil in the box. I only have to move a foot or two for it to bind. Next I will try jacking up one front wheel at a time to see if it will release the torke. I don't want to start buying expensive parts without knowing for sure if those parts are truly bad. If I can isolate the problem to one area I'll buy that assembly. Hopefully I can find the correct test that will reveal the bad parts. Its now a guessing game.
Thanks for your help Trevor and David.
I spent today looking at everything. Every single part is disassembled from the transfer case forward. All bearings and gears look good. I checked the gears in transfer case carefully and they are fine. I looked in the gearbox and carefully checked the claw going into and out of 4wd I can't even think of what else to try.
