2006 Dodge Ram Power Wagon. I have a tap coming from the transfer case while warm and cold, parked and while driving. I have also been getting a in dash service 4x4 light with my axle lock/unlock light flashing.
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i would start with the transfer case . check fluid level and also check your shift linkage to transfer case. also could have worn chain and gears. Is there any grinding noise when you try to shift into four wheel drive ?
The '97 Ram 1500 5.9L 4x4 Transfer case was a Dana mfg unit (interchange # 412-00361 I think). The chain and gears would need to be replaced to correct this. Usually the labor and price of the parts cost more than replaceing the entire assembly depending on how much damage in the case has occurred. You can same a little if you can do the work yourself but the end price comes down to time, ability and cost.
Hi BlvdJoe. I am having EXACT same issue on my 96. I would pull on shifter and noise would quiet down. Changed fluid, no help. This weekend had a new transfer case installed and guess what... noise is STILL there! Mechanics swore it was transfer case as noise would double when pulled into 4-low. I am tearing my hair out. If you found answer let me know at email@example.com
More often than not, inactivity is the number one cause for your issues, and this is a common issue.
What we do here, when this situation is presented to us, is to raise the vehicle up on a vehicle hoist, put the vehicle in 4WD, and we tap on the back side of the transfer case with a large rubber mallet. The tapping action frees off the internal motor, which is usually seized. This is not a critical failure, it is just 'stuck'. Tapping on the transfer case usually unsticks the transfer motor.
Note: Please do NOT attempt this without a vehicle hoist. Using jackstands, aor any other means of raising the vehicle can and will be DANGEROUS to the person tapping on the transfer case.
You need to find out what code it is setting that will make it easyer to find out what is going on. You need a true OBD II scanner to do this. I have had the problem with this same intermitant light. You can check to see if the transfer case wiring is rubbing where the wire go around the trans
Most likely the motor on the transfer case. You have several modules/computers that work the transfer case shifting. Since it is trying to shift, it narrows it down to 2 modules. The transfer case module and the motor module(the motor has a module built in). I do diagnostics, I have the tools to do it. I eliminate other possibilities. Wires and such. I place more motors, than all the others combined. It is the most abused electrical part of a 4x4 vehicle. And it is on the bottom of the vehicle.
shift into 4wd and move truck a couple of feet.
if light is still off, park truck block the wheels set the park brake jack right front wheel and try to hand spin the wheel if wheel doesn't turn 4x4 is functioning properly but there is a wiring problem use an ohmmeter to check the 4x4 switch wiring fuse and bulb
if wheel turns freely the front axle or transfer case is not engaged
attempt to hand spin the front driveshft if the driveshaft will spin the transfer case is not engaged check the transfer case shift linkage, problem is in linkage or transfer case internals
if the driveshaft will not spin the transfer case is engaged properly
with trnsmission in neutral or park start engine measure vacuum on the two vac lines at front axle shift motor . one line should have approx 20" vacuum. other line should have none
if no vacuum measured look for vac leak or bad vac switch
if both lines have vac look for a bad vac swithc or ruptured cad actuator diaphragm
if one line has 20" +- VAC
move transfer case lever to 2wd measure vac again lines should have swapped vac signals
if no vac switch bad or 4wd shift likage needs adjusting
if yes vac motor bad or stuck or shift fork stuck
remove vac shift motor from the axle attach vac lines to shift motor engage disengage 4wd
does shift motor plunger move at least 1/2 inch
no shift motor bad
yes check axle shift fork and vac motor for binging