First, I don't see any difference between Manual and Auto T-case if the part numbers match in both T-Cases. If you trying to find an used one, best bet is to search in Yahoo auction (use proxy service like buyee.jp) to look for and find low mileage one. most of the JDM TD54W transfer cases will match.
The problem started with a clinking/poping/ under acceleration that got worse, initially, I thought it may have been one of the front CVs from the diff to the wheels but it wasn't. I ended up taking it to a mechanic and he said it was the front drive shaft from the transfer case to the front diff. I replaced the CVs on each end of the drive shaft but it didn't fix the problem,
As the mechanic is booked for a month, I decided to further investigate. I drained the oil from the front diff, put a bore scope in, turned the wheels and inspected it, all looked ok. I moved to the transfer case and removed the plugs to drain the oil and zero oil came out not a drop. This is how I arrived at the diagnosis of the transfer case, I am hoping to remove it tomorrow. I wll check the spline for you.
Cheers ... That's interesting that the oil had disappeared. I changed mine at 41,000 km and it was down about 1/2 litre yet the car had never even been driven off road. There was a small leak from the rear driveshaft seal but it didn't seem to correlate with the quantity missing.
The transfer case is in, noise gone, pictures of the shaft that connects to the gearbox, sludge in the transfer case and the bolt at the top of the transfer case.
Mine has a minor damp spot on the rear output seal, 250 ml in a year and nothing showing anywhere else. A drip a day or 2 adds up
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