I have not checked the transfer case fluid yet, I somehow lost my 1/2" 6" extension so have to make a trip to Harbor Freight (over an hour away) to get one. In the back of my mind, I'm really thinking that's what it is.

As far as the zerk fitting in the double cardon joint, I honestly don't recall seeing one today when I took it off but I will double check tomorrow.

 

Ok, so I was able to finally check some things out. I was about a quart low in the t-case, so I filled it up then I got excited because I didn't hear anything. Then today, all of a sudden it started again.

I checked my front driveshaft and do not see any fitting at the double cardon joint. It sounds as thought its coming from the middle to front of the truck. Both differentials have just enough fluid to drip out, so fluid wise, they are ok.

I jacked up the front and tried to wiggle/pry both front wheels and there wasn't any play there. So..... I'm back at a loss

 

Do you have CDL?

You can remove the front shaft all together and engage the CDL and still drive around in 2wd -- I did this for a few weeks while diagnosing my front shaft going caput. This lets you rule out the front shaft all together if that is the culprit

 

Ahhhhhh I do have CDL. I didn't even think about doing that. I'll have to do that in the next couple of days. It's supposed to rain so should be a few good days to be in the garage!