Re: ? on Transfer case & front diff
I don't know what you can do to fix your front diff. They are pretty tough to set up properly, according to some folks I've talked to who do that kind of thing for a living. And from your comment "it has play in the drivers output flange", I'm not even sure what's wrong to tell you to fix.
As far as the Tcase goes, yes, the only upgrade available is the 5 pinion planetary. The 32 spline input shaft is a part that allows upgrading the trans. I don't know of an upgraded chain or viscous coupling available, but new stock parts will certainly be better than worn out used parts.
The 5 pinion planetary was a custom production run. George Blake, a former vendor on here, had like 15 sets made. They certainly were pretty, nice mechanical jewelry. I'm not sure how essential that piece is to have, since there are alot of trucks on here pushing some pretty serious power, and not breaking tcases regularly. They can fail, they have failed, just not the first thing I'd rush out and spend $1500 on, unless you've got money you don't know what to do with.
If you just gotta have one, I think one of the vendors on here took over George's custom bits (input shaft, etc). Don't know that there are any planetaries available for sale....
'JustDreamin'