...went and had a look again and sure enough it had popped into neutral (transfer case) obviously didn't get it in AWD while not running.....
Still doesn't solve my drain plug issue tho...and yes fluid came out when I pulled it originally....

 

I typed up a post but missed you most recent one. How are ya making out with driveability now that the transfer is not in neutral?

 

Does nobody know what this plug drains, why, what, etc.? Guess I'll call a dealer.....

 

I think that's the Detent pin and that's not a good thing. I think you need to pull the case and go through it to see what happened. It's a simple gear case just take it out and go through it, I bet you find out what happened.

PS <--- I see some fatigue fractures, so I would check those out as well.

 

Thanks HS, I put her back together, topped up fluids and everything works fine, save for the mo second gear issue. Can you elaborate a little on the detent pin? I pulled this bolt, some fluid came out, nothing else in catch tub and replaced bolt, topped off fluid and all seems fine.
I didn't notice the cracks, I will have a closer look when I pull the tranny. This vehicle has never been bashed on, I would be surprised that the case would fail in this manner 105k in?
Cheers