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fluid
try checking the fluid level in the transfer case. I am going through the same problem. I jacked the front and spun the front tire and finally found the noise in the transfer case. You need to run 4 wheel drive about once a month and keep the fluid level moving. The noise baffled three mechanics before i found it. the noise was unbearable on the freeways and against sound walls. i just put fluid in last night and it now has a softer click. i KNOW i didnt put enough fluid in....so i'll be doing that this evening....
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