OK I will explain. Last summer I replaced the 4x4 cable. Now when I put into 4x4 doesn't matter if it is Hi,Lo or Auto. I will sometime hear a clicking or light metal clacking sound which appears to come from the front someplace. I don't always hear the sound when in 4x4 only sometimes. Then when I go back to 2wd sooner or later I will hear this sound maybe for 100 km give or take. I have check the fluids and toped upI don't see anything loose. It did not do this prior to replacing the cable.

I'm wondering if maybe the cable needs adjusting, is there an adjuster. Could it be that the axel is not 100% disengaged? All lights are fine 4x4 buttons work great. Also goes in to 4 lo, hi, 2wd and Auto just fine.

Does anyone have any ideas.

 

not to sure, almost sounds like your cable might be to short and that its having troubles engaging all the way

 

or disengaging all the way... have you ever felt like you were maybe pushing the front end when in 4wd. maybe something on the ring or pinion got busted off in your off roading adventures?

 

Disconnect and plug the vacuum line at the axle actuator under the battery tray and drive it. If the noise is gone, it might be that the vacuum switch on the firewall is partially applying vacuum to the axle actuator in 2WD, (there should not be any vacuum at the actuator in 2WD, only in 4WD). The vacuum switch is about 2.5" tall located near the center of the firewall, above the distributor. There is one electrical connector with 2 wires in it and 2 vacuum lines attached to it. This is what it looks like: