yesterday i put my sammy in 4x4 on soft dirt, let off on the clutch witchou much throttle and my transfter case started shaking is but off, and the front end was binding. i was going straight... when i got out to disengage the manual hubs my passenger hub was stuck and i had to roll the sammy a few feet to get it to trun still tough to turn.. any thoughts on what this could be? in 2wd the sammy runs good...

Specs
5.0l ford motor and tranny
stock sammy t-case
stock rear and front diffs

Are you running the same size tires front & rear?
Do the axles have the same ratio gears in them?

put the rig into 2wd before you unlock the hubs.

Sounds like 2 different issues to me...

Transfer case -  take a look at the cradle, skid plate, etc bolts and the case itself for loose bolts, cracked mounts etc. Look at the driveshafts, flange bolts, etc.

Lock out Hub - remove inspect for damages teeth, spring, (repair if necessary), grease, replace...

Are you using the stock t-case mounts?  Check to see if you have torn one of them.

You might want to swap them out for Polaris motor mounts.  Or you can go with the unbreakable mounts from Low Range or Rocky Road.  They are basically a bolt and some spacers, so you could probably make your own from a trip to the hardware store. 

You may also have a broken axle shaft....Boxcar...

Thanks everyone for the replies. I found two issues.

1. the hub assembly bolts were loose to the point it was almost fallin out. I pulled both to clean the reinstalled.....This took care off the binding.

2. since my tranfer case was moved back due to ford 5.0 motor and tranny, the previous owners "welded" there own brackets. lol these welds were horrible so i did a die penetrant test and 3 welds were 90% cracked. i took some tie downs to help support the transfer case just to see if it would help and it did.

Im going to pull the t-case today and design my own craddle like the kong cradle then design some better anchors. when i get finished she wont be moving at all...

I named her last night, FRANKENSTEIN!!! it sure does fit her with all the modifications

Flanny .Can you post some pics of your Zuke for us?? I'd love to see the Infamous 5.0 Zuke..
 ...Boxcar...

I would if i could figure out how. i clicked on the insert image button but all it did was add this to my post

5.0 and samy transfer case and axles drive it easy or things will be braking   

yeah, this wknd is my first mud ride in her. im expecting things to brake. what recomendations do you have as far as axles and transfer case? will the cromley axles with stock axle housing hold up? any thoughts would be greatly apreciated

Yeah I am anxious to see this BEAST too! Glad you were able to hunt down the culprits of your woes. Hopefully your Mary Shelly / Henry Ford creation will allow you some drive time to continue to evaluate the items that are your "weakest links" a little bit at a time.

                                                                               Tux... 

yeah, this wknd is my first mud ride in her. im expecting things to brake. what recomendations do you have as far as axles and transfer case? will the cromley axles with stock axle housing hold up? any thoughts would be greatly apreciated

What size tires are you running? Are you Spua or Spoa? Automatic tranny?

You have the power to run the stock T.C. gears / differential gears. Question is how long they can stand the stress. Same way with the driveshaft yokes and u joints.

Under a load the weakest point is going to rise up and greet you.

No need to go out and start buying a bunch of stuff for replacements until it breaks. My thought is depending on how you drive it you will see what you need to replace fairly soon.

I'm still thinking CJ 5 -7 axles and drivelines  are a good fit since parts for them are available and they supported 304 & 360 displacement motors. I don't think Yota ales drivelins will hold up unless you spend alot of extra $$$ on them because I have seen Chevy 350 motors in Yota trucks and they have problems due to the power...

Just my $.02 

mostly i will be mudd boggin, but occasional trips to arkansas on some climbing. its a spoa with 33x12.50 maxis mudders but will be replaced with swampers once i get everything beefed up.

from what i noticed, my biggest issue is the tourque on the t-case. i figure it will eventually explode and then ill replace it. the axles are prbably the biggest weak link, if i take it easy on them i should be able to get a little life out of them. i was thinking of just going with the cromley axles and the stock axle housing? whats your thoughts?

oh and its a manual tranny, i forgot what kind it is but it came off the 88 mustang as well as the motor so whatever oem is i think a T5.