Play in front output shaft

[KevinNY]

Worn bushing or locking dog maybe? Nut is torqued down properly but there is some play. Thoughts? Especially from those who have rebuilt a transfer case. This a HRTC if that matters.

[I Leak Oil]

Not likely the locking dog unless it's really bad. That just connects the two output shafts together in 4wd. The front shaft is located with the front bearing and the bushing inside the rear of the front output shaft. If either the bearing or bushing is worn that will give you some movement. The rear output shaft is located with bearings front and rear. If these are worn it could give you some play in the front as well, although you would notice play in the rear output too.