I will piggy back on this if I could. Mine goes into 4x4 but makes a clicking noise. I have never owned a CAD equipped vehicle before, so I am assuming that possibly the vacuum might have a leak and is not strong enough and is not fully connecting the axles together?

 

If the light comes on, the actuator is moving its full travel. Still, the little pads on the fork might be gone, giving it some slop, or a selection of other possible problems. Question becomes, WHERE is the noise coming from? U-joints can make a clicking noise as well.

 

Great question. I come from the Jeep world and it doesn't sound like a ujoint click, but something that I will double check anyway. My initial thought was that the outside half-shaft might have chipped or worn splines but a ujoint would be better to deal with.

 

I had a noise I chased for weeks. U joints were tight and had light rust. Well after exhausting all other options I replaced them. I noticed they were dry and the needle bearing had flat spots. So sometimes you just have to change them

 

Yes, true story, been there before for certain!

 

It drive me nuts lol. Just so you know EMS Off-road makes a chromoly axle shaft to get rid of the two piece shaft

 

The front CV could certainly produce a clicking sound at the centering ball and this will often not show itself during the "grab 'n shake" test. Disconnect the driveshaft and work the CV around by hand to really inspect it. Should be smooth

 

https://4x4posi-lok.com/app_dodge.html I'm not a fan of vacuum operated 4x4. I bought the #1100 that permanently locks the CAD. The other problem our Dodges have is the snap ring on the output shaft of the transfer case. You need to remove the driveshaft and tail shaft housing to check the snap ring. Sometimes it breaks, sometimes it pops out of the groove. Check closely to make sure it's not next to the groove and not actually in it. https://www.drivetrain.com/parts-cat...fer-case-saver
The drive shaft will eventually push the shaft into the transfer case until it self destructs.

 

I've done both of these to my truck (1996 1500 with 225,000 miles on it) and have been very happy with both. Definitely glad I'm no longer having to worry about vacuum issues.