Cool! When I saw the title I was wondering if you'd go first gen for that transfer case and low range. I didn't realize how they were equipped until I saw one on the trail back around 2009. We also did a trail with it's mechanical (or near) twin, the Toureg. It was amusing to watch as the driver...
Go Mountain Hawks! Keep any eye on part outs especially if you can get good quality used OEM parts from power steering pumps to torsion bars. I'd think about running that new Valvoline Restore and Protect for several oil changes to clean out the rings. Had that been out, or had I known about it...
I've seen similar issues with CVs binding on sharp turns though it would seem like that would have gotten worse over time. I've had this on CVs pulled from my H3 as well as Bigunit's. Any CV can bind when extended too far, which isn't necessarily the issue here, but could be worn out or poorly...
Transfer case sounds possible given the conditions you've described but then again could be diff, like pinion gear. I've had popping also come from the front diff but that happened in all drive modes with a loose tooth flopping around that appeared more on acceleration as the piece shifted. If...
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