Terrifying experience in my Dodge Ram 2500. MUST FIX.
Common questions/comments answered:
-I am using the recommended oil, Lucas 75-90 Gear oil, recommended by Gear Vendors.
-I considered changing the differentials. It already has 3.73's in it, so I can't gear up much at all to change to the highest available, and I would have to change both the front and rear diffs. More work and similar cost to just going with a new OD, plus the OD simply gives me an extra gear leaving the other gear ratios alone. I still have low gearing when I need it, but also high.
-There's a possibility of 2 simultaneous problems. It's definitely possible that the transfer case wasn't fully disengaging the 4WD, which would make it seem like the wheels locked up. But the problem definitely happened at times when I hadn't used the 4WD for several weeks. Also, I think the OD clutch slipped at least once. In other words, the OD was going to need replacing soon regardless.
-A couple people mentioned that I should have removed the front driveshaft taking 4WD out of the equation to test it. That is a GREAT IDEA and I wish I had thought of it. That would definitively determine if the transfer case was involved, or if it was solely contained within the OD unit.
-The clutch pistons were both free and appeared normal. The one was moving because in the video I had taken it out already and it had air behind it. I just didn't show taking the second one out.
-Many people questioned an electrical cause. I don't think any electrical failure would cause it to lock up. If the speed sensor failed, it would either lock out the OD from engaging, or fail to lock it out and allow it to engage at too low of a speed. Neither was happening, and neither would cause wheels to lock up. If the engagement solenoid was failing, it would either fail to engage, stay engaged, or possibly partially engage. Partial, or rapid fluttering of engagement, would make the clutch slip, or seem to slip. But it would not cause a lockup in any scenario I can see. I think that symptom would also be apparent to the driver, which is was not. Except for 1 instance when it seemed to slip, which didn't cause any squealing of wheels or unsteady back end, the problem always consisted of an immediate and hard engagement with tires squealing and a massive increase in sphincter tone...

Cheers, and thank you all for your comments!

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