BW 4404 Front driveshaft flange has play

[masospaghetti]

For the first time this evening i was able to install a remanufactured front driveshaft in my 96 Explorer V8. No binding in turns, but a pronounced "clunk" when accelerating from a stop.

I got under the truck and found that the front transfer case flange moves fore and aft about 1/8" or so, and makes a clunk sound while doing it.

Does this indicate a worn case? Typical BW 4404 wear? Truck has 149,000 miles on it. Thanks!

 

[masospaghetti]

Found this in gavin's excellent rebuild thread.

Has this c-clip failed on the front output shaft?

 

[imp]

Looks spread out to extent that it cannot hold shaft location. Thus, shaft could move In and Out of case, limited by internal constraints. Big problem? Replace the snap ring. imp

 

[masospaghetti]

The picture above was from a previous build thread, I have not split my case yet. I was trying to determine what parts I might need to limit downtime.

Hopefully the snap ring is my only problem. More worried about a worn out case.