I am not an expert in GMC 4wd systems, but your theory is logical. Try to remove the CV joint first at the transfer case and see if you still have rear wheel drive. This will be easier than opening the front axle case and removing the components. Just take out the driveshaft to the front wheels differential and you should still have rear wheel drive.
SOURCE: 1999 chevy 4wd
hi sounds like a bearing worn on one of the shafts causing a mashing of the gears sorry needs overhaul yates210456
SOURCE: 1999 Suburban 4WD, Noise from the transfer case?
Your problem is similiar to mine . the web-site has been helpful. $2000.00 sounds way to much for repair on that vehicle with such high mileage. I went to a dismantler and bought a used transfer case for under $350.00. Did the labor myself with a little help. It's not too difficult if you have a some diy experience or ability. As your working on it stay with the web-site for install hints or go to autozone.com for repair diagrams.
Good luck have a good day.
SOURCE: front drive shaft/transfer case removal 03 chevy trailblazer 4wd
Sounds like you got it. They are heavy and ocward (spelling?). As for the front drive shaft take the bolts out and give it a couple of wacks with a dead blow hammer then slide it out. Maybe a few days before hand give it a good spray down with wd40 or like product. Also when you get to the last bolt for the t-case to trans loosen it half way then put a drain bucket under it and seperate it a little and let the trans fluid drain some, or you will be wearing it.
SOURCE: GMC '91 Jimmy, Transfer case. When in two wheel
Yeah your right about waer but you might be blaming the wrong part. With the truck up on jack stands ( all wheels off the ground) have a helper drive the truck at the speeds that make the most noise you'll find it in the front axel or fround U joints or drive shaft splines ( drive shaft jumping ) You watch the parts moving and the joints or the cable that shifts the ront axel in and out not moving all the way it uses a vacume motor under the battery that has a cable going to the front axel. the clutches that are in the front axel have clips on them that hold the side gears that engage and disingage as you turn it on and off the clips break get lost fall off were out and let the side gears do as they please and they runinto each other a click and pop/ the cable and the shift fork that move them also fail but not htat much as the cable fails and the vacume leak pulls on a spring in two wheel and it may not be pulling hard enough/
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