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