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OK, you said it was locked up even after you pulled it off? Then it freed itself right? Just makin sure I understand you. There is something seriously worn out in there. As far as the bolt goes, I would just use a BIGGER wrench and get some muscle on it. Thats what I did (I used an...

IMO, unlikely. It would have to be one helluva flat spot (broken ball).

That big sliding gear is first gear. The rod sticking out the end is for the sprag. If your truck has an air shift transfer, it wont be connected to anything. The correct TM for top cover disassembly is: TM9-2520-246-34-1 (pg. 2-36) Basically, you undo the wire ties so you can unscrew the...