New to the Forum but have been reading posts for years to help fix my 03 Ram 1500. I had no luck scouring posts to find this issue so here goes....
Like I said, 03 Ram 1500 4.7 L 4x4, 215k. Last winter I used my 4x4 and was hearing a loud clicking when I turned, left or right. Never had to use 4x4 after that so left it along. This past fall my passenger side CV axel snapped. Obviously I replaced it, thinking it would take care of my clicking while turning in 4x4 issue. It didn't. I did reuse the trans axel on that side. A month ago I swapped out the driver side CV axel and trans axel, once again hoping it would fix my clicking noise. It didn't. Was under there the other day trying to figure out the issue and noticed more play in the passenger side axel than the driver side. Did I mess up by not changing the trans axel? When I pulled the trans axels out and inspected them, they were clean, no metal shaving or scratches. What is causing the clicking, it feels and sounds like gears are slipping.

 

Ok, maybe I need to explain a little better......I have been driving this truck for over 13 years, I have driven it on every condition in and out of 4x4. I've replaced ball joints, upper and lower control arms, cv axels, hub bearings, rotors and brakes, ac compressor, water pump 3 times, radiator more than once, even changed out the blend doors because I didn't have defrost....the right way by removing the dash and ripping apart the plume box. I am going to be pulling out my oil pan soon to fix a leaky seal but I haven't decided yet if I want to drop the front diff or take the motor mounts off and jack up the engine. My point is, I have never heard or felt this issue with the 4x4...and when it occurred I was on slushy road conditions. I guess my next thing is to pull off the front diff cover and inspect the gears.....any suggestions would be welcome.

 

Clicking when turning can be CV joints, and I also have heard of loose sway bar links causing a click in turns. You may want to tighten all four connection points of the front sway bar links and see if the noise changes.
You mention a leaky oil seal, be sure to check the torque on the pan bolts. They are 130 inch/lbs and can work themselves loose.
I"m a little lost on your description so I won't be much help. You mention replacing the CV axle, but re-using the transaxle. I don't know what that means. Some part numbers or pictures would help.

 

Thanks for the suggestions on this issue. I've checked all the bolts on the sway bar and they are torqued to specs. The Trans axel on the passenger side is also known as the Front Axel Shaft, Dorman part # 630-415. We actually have a snow and ice storm here today and just took the truck out to ensure it is not the 4x4 Bind up that was mentioned in another post. Unfortunately, it is still making a clicking noise while turning in 4x4 with snow and ice on the roads. The only thing I can think of at this point is to replace the Front axel shaft on the passenger side and get into the front diff and check the gears. Other than that, I am at a loss.

 

Got the truck all torn apart, again. I decided to replace the Front Axel shaft, the hub bearing, and possibly the CV axel (even though I just replaced it 4 months ago). I am going to tear into the front diff and see what's going on in there. Will post more tomorrow when I get done. These are the old parts...

 

Well changed out the hub bearing, CV axel, front axel shaft, and pulled off the front diff cover. The gears in the front diff looked great....no marks or metal shavings in the oil. Put it all back together and test drove it. Still making a nasty clicking noise when turning in 4x4. This is an issue I need to address. I guess my next step is to move back to the front drive shaft and transfer case. Any advise would help.