Chevy 2002 2500 series, 4x4 will not engage, when shifted into 4wd a kind of grinding noise comes from the front like gears are not meshing.

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4x4 not working - Ford F150 Forum - FordF150.net

inspect for worn components from output of transfer case to front diff input. If everything is tight and solid from those two points, everything else points to being transfercase internals. Make sure your actuator isn't faulty causing a "4x4 to 2x4 shift on/off"

Check for the sensor on the transmission

4 wheel drive trucks make this sound alot im guessing its a manual shift so i would saw that the meshing is more of a grinding instead so i would have the transmission rebuilt to fix the problem or just see if the rings inside the trans. is missing the tooths on it :)

sound like the shift motor or shift gear in transfer case that makes it go into 4WD.sound like gear damage or worn

You say 'new' truck, 09? or new used? I have had 3 Fords, 3 w/ manual trans. case, if you go into 4x4 Low range, you must come to a complete stop before shifting the trans. case to 4x4 mode, and I always put trans (automatic) in neutral before slipping into 4x4, it engages smoothly, no grinding. 4x4 high range can be put in while moving, but I would let off the gas pedal, shift to 4x4 high range, then resume accelerating. If there is any grinding going on doing it as above, something isn't right. Check the trans. case fluid level also, to make sure that's not an issue.

This sounds like the famous problem that those ten bolts give, remove the rear differential cover and inspect the oil for metal debris, it's more than likely to be the carrier bearings wornout making the ring and pinion offmesh causing the grinding and will eventually break. Hope this helps

check clutch slave cylinder and or adjustment

you may have a bad transfer case

My 2003 F150 Supercrew would not engage in 4x4, it ended up being the shifting fork in the front end, cost me $200.