2nd Gen Non-Engine/Transmission dana 60 front

[horseman]

i have a 95 2500 5spd and when i put the truck in 4wd all i hear is grinding in the front axle and the front wheels do not engage. It will stop when its not in 4wd. Sometimes when i let off the throttle i get a bunch of rattling and grinding, when i give it throttle it will stop. This doesn't happen all time but getting more frequent any ideas to what that could be ?

 

[DCreed]

check fluids? look for slop in the U joints and pinion. and be sure there is good vacuum to the 4wd actuator on the pass side of the axle. also check transfer case fluids and slop.

 

[hackengineering]

Definitely check that actuator and make sure it is fully engaging. It may have a burr on one of the shafts now allowing it to fully engage. Since you say it is not engaging i would focus on that first. Other wise it will most likely be your t case. Jack up all four tires and put the truck in 4 wheel and see if you hand turn the front drive shaft if anything is engaged.