noise from just put together transfer case!

[06boblee]

I pulled my transfer case while I was cleaning and painting the frame. I could determine nothing wrong with the TC except every seal was leaking. All of the flanges turned well with no free play. The lube was drained and was just barely black.
I took it apart and inspected all of the internal stuff and the bearings. Everything looked great so I cleaned everything up, installed new seals and gaskets and put it back together. used the proper thickness gaskets.
Now when I got it completely back together I was turning the input flange, checking that the shift rails were ok, and everything was functioning right. That is when I noticed that in low range all was great everything turned smoothly and quietly.
When I shifted to high range and turned the flange I hear a faint "clicking". If I turn it really slow I can feel the click. It sounds like it is coming from the idler shaft area, or maybe the output side. It makes the clicking sound forwards or backwards, but in high range only.
Anyone have any ideas? I am assuming that it should not do this,
While it was apart I did spin the idler gears and they were smooth and quiet, I did not remove them as they seemed ok.

[ashyers]

Make sure your safety wire for the forks isn't touching the output gears.

[06boblee]

Make sure your safety wire for the forks isn't touching the output gears.

Well, I thought I had them tucked up well. I have ordered another set of gaskets since it looks like I'm going back in.

[06boblee]

Make sure your safety wire for the forks isn't touching the output gears.

Well that was the problem! Boy am I glad it was that simple. Thanks Ashyers for the heads up on this. Now to wait for new gaskets to seal it back up (again).

[ashyers]

Ask me how I guessed what it was...

Glad to hear you have it sorted.

Andy