Front end rattle and vibration

Hi - Love this site, thanks for all you do!

So, about 8 months ago, (about 60,000 miles) I switched from 2 to 4 wheel drive and heard a loud pop when starting to back up. I did a quick visual inspection (loose anything, fluid drips) before proceeding. All looked well, so I backed up the 40' off-road (with a bed full of tools) without further issue. 60 minutes later, when back on pavement, switched back into 2 wheel, no problem, and went on home.

This was the last time I've engaged or disengaged 4 wheel drive.

Approximately 3 months later, started hearing a ticking noise that sounded like a wheel hub going bad (rate of tic increased and decreased with speed). Found a great deal on new parts so I replaced:

Hubs, rotors, pads, tie-rod ends, sway bar links, upper control arms and lower ball joints - both sides. Tires are about 1 year old at this point. Admittedly, I've not gotten a proper alignment since the front end work, but it wasn't much off and I'm a professional procrastinator. Hey, it is what it is.

Ticking noise was gone. For about 30 days, then returned. Has been progressively worsening, until its more like a grinding. About 2 months ago, it got dramatically louder. I crawled underneath & discovered 2 holes in the transfer case housing. I made contoured plates as patches, pop riveted in place and sealed around them with 'quick steel'. I have no idea if there is supposed to be fluid in the T-fer assembly, but since there was no evidence of any, I didn't put anything in.

Grinding noise has continued, of course, though not worsening. No loss in power, acceleration, etc. Over the past 3-4 months, a "wub-wub-wub" sound has joined the choir.

2 weeks ago, it suddenly developed a nasty vibration, and I was nervous to go above 40 mph. I drove it twice, less than 2 miles each trip and on the last outing, the rear propeller shaft bolts sheared from the rear differential. No real damage done, so I reconnected and replaced the U-joint.

All noises and vibrations remain, I still won't go above 40 - but now it pulls to the left rather dramatically and has difficulty getting to speed. Like I'm pulling some real weight.

I don't have the cash to take it somewhere, I don't know where one problem stops and the next one begins. Hoping for a starting place at least because I'm ready to light a match and watch her burn. I love/hate my Dakota!

Thanks, truly!
Michael - Indy