May be the problem is not in the actuator in the case but in the actuator that engages the hub locks . Check for vacuum line / electrical wires faults . The noise may be from the hub lock or from a cv joint in that side.
SOURCE: 05 f150 4x4. 4 wheel drive lights come on but it is not engaged?
change actuator in front hub water gets in there freezez and ruber seal rips part only 120.00 bucks not hard to change beat upper ball joint take of spindle nut think it was 5/8 3 bolts in back should fall out
SOURCE: Ford F150 front tires won't engage in 4 wheel drive
look on fire wall pass. side you will see 2 parts with vacume lines attached 99 percent of the time that is what went i had the same problem
SOURCE: Front drive, 4 Wheel drive won't engage
Check the switch on the transfercase remove the vacume lines if there is oil in them the switch has to be replaced and the lines should be cleaned out you should also check under the battery tray to make sure the boot is not ripped that controls the leaver to engage the front axel
SOURCE: 1996 suburban makes grinding noise in 2 wheel drive
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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