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I used to own a '95 and had numerous problems with the 4wd (usually resulted in my getting stuck somewhere). The pause in engagement is normal, and depending on the temperature and alignment of the gears it can take quite awhile.
Right now I've got a '98 that is stuck in 4wd high (i've always wanted an all time 4wd vehicle!!) and getting about 10 mpg. Acuator problems I'm sure, but don't have the time to address it right now.
On the subject of "glasspacks," you can get by with having basically no muffler on your tahoe. Get the person installing your glasspack(s) to put them in backwards and the exhaust will flow straight through them just like a straight pipe!
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