So, at a decent rate of speed, like 35+, If I decelerate while in 4 Hi, I get a lot of chattering noise from the t case. It seems like there is a lot of slop at the front output on the t-case, and I just put in new U-Joints. Is there a bearing or something allowing all the slop?

Just to make sure... not sure what changes you have done to the car so far.  Do u have lockers, lower gears in diffs and/or tcase? I think you have a spring over?. I ask because because in the divorced tcase system that the sammy has, slop or angles of drivelines is magnified.  Also is this under engine compression or the clutch disengaged?

Is this when driving around on pavement?  These transmission are not designed to be driven over 25 on high traction surfaces.  It causes binding and may result in what you are seeing. 

Is this when driving around on pavement?  These transmission are not designed to be driven over 25 on high traction surfaces.  It causes binding and may result in what you are seeing. 

I am in double super-whammy agreement with the above statement!

Driving a Samurai (orTracKick or ANY similar part-time 4x4 vehicle) on solid dry pavement in any 4wheel drive mode is ASKING for mechanical trouble!

Samurais (and TracKicks) do not have the central differential or viscus coupler required for full-time all wheel drive capability.

Don't even THINK about doing it!

Quote from: Drone637 on December 31, 2010, 11:35:05 AM

Is this when driving around on pavement?  These transmission are not designed to be driven over 25 on high traction surfaces.  It causes binding and may result in what you are seeing. 

I am in double super-whammy agreement with the above statement!

Probably because the information came from one of your posts. 

Clutch in or out. In Gear, or not. There is a lot of slop on the front output shaft of T Case. Not Driving on dry pavement, but snowy Colorado roads. I can hear a lot of noise? Is there a serviceable bearing up there, or should I just grab a New T-Case and call it a day?

I found some rebuild kits, so I'll probably go that route.

There are two reasons for a loose front output. First is a worn bearing. I have broke the c clip that holds it in its seat and have the bearing go out. You dont have to disasymble the whole case to fix it. It can be a bear to remove the bearing. 
The second reason could be the tit on the back end of the output shaft that goes in the pilot bearing on the main output shaft. The bearing could go out OR the tit is broke off. I have had this happen when i have landed the fron drive shaft on a rock. When this happened to me it felt weird when i would put it in 4wd.

Keep us posted as i am very interested in the answer. I have rebuilt over 30 of these and also machined my own cases.

I ended up contacting a buddy who worked at SpiderTrax a while back and he sold me a 4:16:1 Cheap. Got some 5.12's and some doors too!

Nice.  Time to get some new tires. 

New T-ase is in! I love it! Can't wait for 35"s