1996 2500 hd 4x4 makes grinding noise when accelerating in 2 wheel drive. sounds like transfer case is trying to engage. if you put it in reverse and nail it, it makes tremendous clunk and revs up as if it was in neutral and stops. 4 hi and low work fine.
Sounds like the clip on the rear output shaft its probably broke. do this by removing the rear driveshaft, and the tail of the transfer case, there are 4 bolts holding it in place. then grab the output shaft and see if it has any front to back movement. if so pull it all the way to the rear and you should see a groove at the front part of the shaft where the clip goes. Then you should find the pieces fo the clip in the tail housing. One person said he found the replacement clip at a local tranny shop. I am calling the dealership parts counter for a new clip for my 97 Tahoe tomorrow. Hope this helps..
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I have the same problem. I have a 97 Tahoe with push button 4WD.
I can assume that your 2500 HD has push button as well.
I was told it might be the actuator motor that shifts the 4WD running when it shouldn't. I was also told it might be a clip on the rear output shaft of the t-fer case has broke. I was told to remove the rear drive shaft and check for severe play in the output shaft front to back. if so, remove the rear tail housing (4 bolts) and you will find the shattered key in the housing or on the ground. You can get a replacement clip at a tranny shop. Once I find and fix my problem, I will post it here.
Any feedback from anyone else ?
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