I have a 03' Ranger Fx4 level II, 4.0L V6 SOHC, Trans is a Mazda 50D R1 HD and the Transfer Case is a Borg-Warner 1354.
My transfer case keeps slipping and nocking when i have it in 4HI, i think the forks are just worn, but i'm looking to do one of two things.
1) Find a different transfer...
had the same thing happen to my truck it takes some elbow grease but if you replace the rear pinion seal it should fix the problem. its a really tight fit.