97 Transfer Case Noise

My '97 4WD Tahoe started making grinding noises when accelerating. It turned out to be grinding caused by the front wheel drive trying to engage without pulling the lever on the floor. I messed with the shift lever, but the problem persists. When I rotated the front driveshaft by hand I could feel it trying to grab. I have now pulled the front driveshaft and am driving around with the shift lever in 4WD mode. This stops the noise because the front drive in now engaged in the transfer case. Has anyone else had a problem with the front wheel drive trying to engae itself? What is the fix? I am assuming something is worn in the transfer case but don't really want to do exporatory surgery.

i'd say it's either the actuator in the front diff of the switch on the top of the transfercase that sends power to the actuator.

Also sometimes the snap ring breaks at the rear of the output shaft. This lets the shaft walk back and forth. Along with quick jack-rabbit starts it will sometimes make the noise when the automatic transmission is shifting from 1st to 2nd gear.

The rear most extention housing needs to come off the T-case(while in vehicle) to verify the broken snap ring. Just another Idea for you.

Stay cool

Sorry...don't know. My truck has the electric/push buttom 4wd.