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I was driving the other day and decided to switch on the 4wd. It had been a couple months since I had last used it. So it switch on, no problems. When I started driving there was a clanking sound and my truck was catching every 15 feet or so. When I go a little faster its about every 30 feet, but the clanking sound gets way more intense.
Any ideas on what might be wrong? I would rather not have to take it to the dealership.
Verify that your tires are relativly the same tread depth and inflation pressure. Any variation in overall tire circumference can cause issues with your 4x4 that will make it feel like it is binding. Keep in mind too that if this is on dry pavement, you WILL get some clunking noises that are inherent with any 4x4 vehicle. The problem is when you drive there are many variables that require your tires to rotate at different speeds (such as during a turn, your RR tire does not have to move nearly as far as your LF tire). So when you lock all of your tires together in 4x4, and are on pavement (does not allow your tires to "slip") you will get some binding sensations, and invariablly some noise such as grinding/clanking as well.
If you believe this noise is still abnormal, take your truck down a gravel road and see if the noise is still there. If you still have a noise down the gravel road, then further diagnosis may be necessary.
Do not engage 4WD on good pavement or concrete surfaces where traction is good. Even the variations in load on the tires and air pressure variances will cause windup and severe stress on drivetrain.
Good to engage 4WD regularly, but do it on a slick surface like grass or loose gravel.
Sounds a bit like the noise I was having which was caused by a vacuum problem created by the IWE solenoid. Of course, mine was happening when in 2WD randomly as I drove; terrible clanking/grinding noise. Replaced the solenoid and no more problems. Makes sense to me, that when you engage the 4WD, if the solenoid does not operate correctly, you too may be experiencing noise caused by the IWE's not completely engaging.