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The grinding and difficulty shifting out of 4x4 Low in your 1991 K1500 could be due to a few possible causes:
1. Transfer case issues: There could be a problem with the transfer case itself, such as worn gears, damaged shift forks, or a faulty shift linkage. This can result in difficulty shifting out of 4x4 Low and the grinding sensation.
2. Synchronization issues: The synchronization mechanism in the transfer case may be worn or damaged, leading to difficulty disengaging 4x4 Low. This can cause grinding as you try to shift it out.
3. Clutch or clutch linkage problems: If the clutch is not fully disengaging, it can prevent the transfer case from shifting out of 4x4 Low smoothly. Issues with the clutch linkage, such as a worn clutch linkage bushing or misadjusted clutch pedal, can also contribute to this problem.
It is recommended to have a qualified mechanic inspect and diagnose the specific cause of these symptoms. They can perform a thorough examination of the transfer case, clutch system, and associated components to identify any faults or wear. Once the problem is identified, the necessary repairs or adjustments can be made to resolve the issue with shifting out of 4x4 Low and the grinding sensation.
Check the sensors on the transmission. May just be corrosion on the sensors or it may be a faulty sensor. Also, the torque converter bearing may have went bad due to the running it on low transmission fluid.
It sounds to me like your gearbox is knackered, but just to be sure get underneath & check all the linkages, get yourself a workshop manual as linkages are easy to fit even for a novice, solenoids are relatively inexpensive so if you don't feel like doing this yourself then try this route first.
You will need to chock the wheels for safety, and then remove the linkage to the tranny, located on the driver side of the transmission. Once you do that manually put it in park and see if that works. I had a similiar problem on a 99 gmc sierra after I had replaced the tranny. As it turns out it isn't adjustable (the linkage) so once I did the above, and it worked fine I had to figure a way to adjust for the half inch it was lacking in order to fully be locked into park (which also caused me to start the vehicle in nuetral). The bracket that the linkage was mounted to was also solid, and not adjustable. So I removed the linkage, and used a small crow bar and a 3 lbs sledge hammer, and bent the bottom of the bracket forward the half inch I needed. I normal don't modify things like this, but the folks over at GM left me no choice in the matter. It has worked fine ever since, and the bracket was so hard that it hasn't attempted to move back in anyway. It may be worth a look. Good luck...
sounds like a mouse has got in and chewed the cables,their is no easy fix from what i can think of but check all the wires and connections in case water has got into it,or snow if your in alaska.its fifteen years old now so its possible that some insulation has broken down or a wiring loom has chaffed somewhere underneath
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