My 2000 dodge ram 1500 slt club cab 5.9 has a loud popping kind of noise coming from transfer case when 4wd is engaged. sounds like a chain is slipping on a sprocket. when it makes the noise it kind of jerks like it is slipping. but the 4wd is actually engaging you can feel it but obviously something is wrong. could it be the transfer case chain?
Inspect for worn components from output of transfer case to front diff input. If everything is tight and solid from those two points, everything else points to being transfercase internals. Make sure your actuator isn't faulty causing a "4x4 to 2x4 shift on/off"
SOURCE: I have a gmc sierra
Alot of people are having this problem. A locked 4x4 while turning on a dry or wet surface will do this, unless it is snow or mud which allow the wheels to slip the front wheels bind and buck,clunk. Now if this is not the case then check the CV joints, jack front wheels off ground, one at a time is fine, grab wheel and wiggle all around and see if tire feels loose as it might be a bad wheel bearing hub also. I don't believe there is anything wrong with the ,transfercase. I have owned 4x4s for 31 yrs ranging from 1967 - 2003, mostly chevy (gmc) ford, and 1 dodge ram. 9 out of 10 times it is front hubs,pinion,front driveshaft. Transfercases either work or they don't,and if they don't its because it's broke and your not driving.
SOURCE: 1989 2500 4x4 Transfer
if you have to lock the hubs Manuely thay need to be rebuilt /if thay are automatic same thing first have some one look under the truck and make sure the drive shaft is turning if you find no problem's with what was looked at the last thing to check is the ring and pinion in the front rear good luck
SOURCE: The 4wd won't engage on my 2007 ram 1500 SLT
Could be the motor, but they usually last alot longer than four years. I would check the wires and plugs first. Check for corrosion in the plugs, bend the tabs in the plug alittle so they get good contact. check the wires at the back of the plug, this is where they tend to break, give them a tug, you wont hurt them unless they are broke. Make sure that none of the transfer and transmission wires are not hanging down. if they are check these areas for damage and resecure them up to the transmission. Also while your under there check for oil leaks. If you have one on the transfer case, remove the top plug. Oil should come out of this hole, if not then fill till it does. Transmission fluid is what you use in this. But check your manual first to make sure there isn't a synthetic oil in there. if there is you can drain it and put in transmission fluid, or spend $32.00 a quart to fill it.
SOURCE: have 99 dodge ram 5.8
If you have verified that the transfer case itself is engaging into 4wd, then this is where I would begin my diagnosis. On the front axle, on the passenger side, you have a vacuum actuator that moves a fork in your front axle. The should have two vacuum lines running to it, one red and one black.
You will want to verify that you have vacuum on one line while in 2wd and no vacuum on other line, with engine running.
If you have vacuum on one hose in 2wd shift to 4wd and verify you have vacuum on other hose, and none on other. If vacuum is operating as supposed to, you will want to remove the actuator cover from the axle and verify that the fork is sliding on the actuator and is not binding up. It is very common problem on these for the actuator rod or fork to bend, causing binding and lack of 4wd.
If vacuum is not present, trace the lines from the front axle to the transfer case verify all lines are hooked up and not damaged. They will attach on the transfer case at a 4 way vacuum connector on the top driver side of transfer case.
If these lines are okay, you will want to verify you are getting vacuum from the engine to the transfer case. If not follow the line up to the engine compartment and find broken or damaged line.
If you have vacuum at the transfer case, but nothing coming through, the vacuum selector switch in the transfer case is bad and will need to be replaced.
Make sure you have vacuum. This is critical. It should be whatever engine vacuum is. If it is weak, it may not be enough to move the actuator and can also be caused by damaged or kinked lines.
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I had a 4x4 year ago. Do you have front locking hubs ? I don't think so if you did I would ask if they were in or out. If there is nothing else It has to be coming from the transfer case. As far as I know no manufacture makes a true 4 wheel drive but Jeep except for maybe Raptor or Power Wagon. Most come with an open diff in the rear one wheel drive unless you order it special and the front you can't even order a locker if you wanted to 99.+% of 4x4s have open diffs in the front. Jack up one front wheel and one rear wheel if you didn't order a special rear end if you try to drive off the jacks you will sit there and spin your 2 wheel drive and not move.Ford says if you have worn tires or not the same air pressure in all tires it will do this. I think you have a bad u joint or pieces broken in the transfer case or it is out of adjustment. Jack car up like I said before and when the wheels spin without pulling it off the jack stands crawl under and see where the noise is coming from front or transfer case.I wonder if your shift motor could be bad they are about 65 dollars
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and this is in snow too. not on concrete or anything...
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