Ok, I've got a 93 Grand Laredo, 4.0 I-6, selectrac 4wd (4wd part time, full time, & 4-lo), Automatic. When I have 4wd engaged and I'm turning the wheel or when there is more load on the front axle than flat ground (i.e.-hill climb or deep mud) you can hear a popping or cracking sound from the axle. The turning the wheel makes me think that one/both of the universals are bad, but I've checked them and they don't leak, have plenty of grease, and don't have any play.
However, the Front driveline has some play, and I can hear a click coming from the front diff. But I've heard that some play is normal, to prevent shocks to the system or something like that. I've had the diff cover off, and there's no shrapnel in the fluid, or any visible damage to the gears that I could see. So, do I have bad spider gears, or a turned axle shaft, or what? The u-joints in the driveshaft are fine too, no play whatsoever. The thing is, 4wd works fine, and I have no problem getting into or out of trouble with it. It just makes a lot of noise when it's under a load.
I'm not bad with cars, I'm actually usually pretty damn good, but this one's got me stumped. Help!!!
PS- no oversized tires or anything, just standard 235's.