Gen 1 IWE replaced

[rschap1]

It used to shift nice and smooth even at speed.
I do like the thought that cvs, axles, and front dif isn't rolling around in 2wd.
Save some wear and tear.
Thought if I ever do front springs or go to mid perch the extra bit of angle on the CVs would be even better to be able to un-lock at the hubs...

I am pretty old school (and just old) myself.
Still from the days of manual lock outs and gear drive transfer cases, so I do share some of the same "fear" when "shifting on the fly".

 

[rschap1]

Seems better now.
Replaced the passenger side Friday.
First trip around the block was better, but not super smooth or quiet.
6 or 8 switches from 2wd to 4wd and now it does seem good.
Made a trip to watch Midwest Dirtfest and flipped in and out of 4wd without noise, clunk, or issue.
Hopefully all set.

 

[rschap1]

Swapped another new IWE onto the driver's side again yesterday.
Yep, gets easier and quicker each time doing it


or really I guess-having to do it again.
But same issue again now.
Pretty harsh, solid, clunking sound when engaging 4WD.
Everything seems to be OK, old stuff looked good when taken apart and installing new IWE.
Used a little more grease on everything this time.
Thought that may help things slip and slide together a little easier.
About the same as previous unit.
Just seems and sounds pretty harsh when the IWEs engage.
The last one did good for a few tries, then got to where it was noisy again.
The old ones were smooth and silent.
These both seem to make a pretty noticeable clunking when going anything over 25 mph.
I have only shifted them in a couple dozen times just to trial on passenger, and about a half dozen times on driver's new one now.
Anyone else had same?
Wear in?
Wondering if I am just missing something here or if "normal"?

TIA