Seriously.... plus now s#!tposting in someone else's thread about a water leak for a totally different model... I suspect you will get your posts deleted and possibly banned.

FYI - on many 4wd and awd trucks - GM, Dodge, AND Ford use the same Borg Warner transfer cases with minor differences.... So you might have the same crappy luck with your beloved Ford. None of the brands make transfer cases.

 

And...... what brand replacement shafts have you been using? You want help, answer the question. Us ACDelco parts and it should not be an issue.

There have been many people who went the "cheap as I can find it" replacement half shaft only to find out that said cheap part was too short, and chewed up splines in the carrier end making a simple repair a major multi component job. When the splines get mauled, the shafts can get stuck in the carrier end. Don't know if that is your issue, but I and others are trying to offer help.