Hi. Just picked up a K74 2004 Animal 2.5TD and couple of days later we have the 4x4 light flashing and grinding gears noise at idle. Noise disappears when clutch is put in and it is while the truck is not moving. So from what I have already leart it is nothing to do with vacuum. Is that right?

I have checked the error codes and I see codes 21, 22, 23, 26 and 32. As far as I can tell it means - Transfer position switch system - Transfer shift mechanism malfunction/ actuator malfunction.
But I also read that 4wd is engaged mechanically via the lever, not an actuator? What am I missing? Any idea why it sounds like the gears are grinding in neutral?

It still drives, sort of, but not intending to drive it until I identify what is going on.
Thanks for any guidance you give me.

when you select 4WD there is a little plunger (actuator) on the front diff that engages the front hubs operated by the vacuum system
sometimes they can stick, so pull back the rubber bellows and squirt some WD in there to make sure it's moving freely
If you've got a flashing 4X4 light all the time you've probably got a vacuum leak somewhere
if the plunger is not engaging or disengaging properly you get a clicking/grinding noise when moving/rolling that should stop when stationary
remember to only select 4X4 mode if you are on a loose surface or you'll do some damage to the diff

r u sure it is grinding and not a rattle

Hi

krutly
I don't think this is anything to do with the front axle. It makes the noise while stationary so there is nothing rotating in the front axle.

123hotchef
I think you're right. I'm now thinking clutch release bearing. Not sure why I didn't think of that before. Is that what you are thinking too? I'm trying to get hold of a workshop manual but seem to be having isues with my email. I'm guessing its a bit of beast of a gearbox to remove and refit?

Thanks
Lee