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I had the same problem in the front end ,99 Exp.,I did not notice a problem in the rear. The front end would groan if you accelerated or turned, if you stopped it would go away. I needed new tires and I had mismatched tires on front and back. New tires of the same took care of the groan. I think that the sensor may have recognized a difference in tire turning speed and thought it should engage the 4X4. My next step would have been to put the back tires on front and front on back to see if that took care of it. 210,000 wonderful miles and I think my sensor was getting a little tired
ok guys am back took some time to get sorted out and a warm enough day to get under the truck... tried tires not luck... tried the fuse still no luck....tried unpluging the shift motor ...nada still engaging when turning as far a the graon put some lucas in the tranfercase and front diff and graon went away (not sure which one helped ) but not the binding\hop when turning...this weekend i removed the front drive shaft and all went away .. back to normal so i am stuck on which direction to go now... it is working fine as a 2wd (no drive shaft)and turns no problem...do you all think it could be speed sensors or just the transfer case shot.
Sounds like this binding/hoping is coming from the inside rear wheel when turning. Do you have a limited slip rear diff? If so, I don't think it is slipping as you turn.
I'd try jacking up one rear wheel, and with the transmission in neutral, see if you can rotate the rear wheel that is off the ground. You might need a breaker bar to rotate it. If you can't rotate the wheel, the limited slip is either too tight or you might need a better additive.
(Just as data point, when I rebuilt the rear diff in my '79, I set the traction-lok clutches up way to tight (even a quarter turn of the steering wheel would start the inside rear tire binding and the whole truck would chatter). I tried a tube of no-name limited slip additive from the local parts store. It made no difference, even after 25 miles. Not trusting that no-name additive, I then added a 4 oz bottle of Amsoil's 'Slip-Lok' differential additive and within 50 feet the problem was solved. (I'm not pushing the Amsoil product, just making the point to use a good additive.)
If the front tires are worn and not the same size as the rears, you will experience this problem. It confuses the system and engages the 4x4. Get new tires if needed and proper rotation will illiminate this.