Transfer case noise

[win32exe]

Hello, i have an odd issue, my SX/4 was running fine in 2 WD, winter is coming so i decided to put it in 4 WD, it didn't make it to 4 WD smooth and was making a clicking\knocking noise like it wasn't all the way there, so... i decided to do away with the vacuum actuators all together, so i locked the front axle in place as described in another article here, locking the fork shaft with a hose clamp, that seemed to go smooth.

i proceeded to use metal stock and created an arm to attach to the pivot on the transfer case and ran up thru the floor, now i can shift from 2 WD to 4 WD, it goes in and out but makes the same noise like its not all the way in 2 WD or 4 WD, but it does drive, i am going back and forth in my driveway, not long distance on the streets.

what else could it be? it wasn't making any noise when in 2 WD before i attempted to shift in 4 WD for the winter.

i have enough shift throw for the pivot to go end to end.

what else can i do\test to eliminate possible causes? like lock the front axle in 2 WD?

Thank you

Henry

[win32exe]

as i continued to think about this, it occurred to me, with a little logic and inquiry, it's the front drive shaft hitting the exhaust pipe right where the u joint bosses are, i am going to remedy that and see if the clicking goes away.

when i locked the front axle that allowed it to make the noise when in 2 WD also?? right?

Henry

[89 MJ]

Locking the front axle should have made it so the front driveshaft is turning all of the time, yes. Hopefully that fixes it for you.