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I very, very rarely put my 2001 F-350 PSD in 4x4. But I had to last week pulling my 9000lb trailer slowly, about 2 miles through the desert sand. When I would accelerate up a hill or slope my transfer case had a mild grone. Is this normal. Should you be able to hear and feel when you're in 4x4?
Could be a bearing that was, or is dry from not being used. Were you in low range, or in high range? Low range will make some gear noise, and I can always tell when my truck is in 4wd. Heak I can even tell when the hubs are locked and the t-case is still in 2wd.
Once you determine the problem, you should probably consider engaging 4wd a bit more often, or at least drive it some with the hubs locked.
i can hear my t-case growl when i am in 4-low but in 4-hi you should not notice a difference unless you are at a high speed. but then you would notice more vibration and more noise from the front end.
you NEED to run 4-wheel about once a month. even if its just for a mile or so, lock the hubs and and go to town. its the age old saying... you dont use it, you will lose it! very true in this case. the bearings will get dry and metal to metal will touch, the seals will dry out and start to dry rot and then leak, the shifting mechanism can get stuck in one position from no movement after so long, etc, etc.
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