1999 dodge 1500 5.9 v8 magnum 4x4 make a grinding noise when pressure is applyed

Yep, this group's as bad as ever ... twenty days and no answers for ya.
Ok, a stab in the dark since you didn't mention what transmission you have and I don't know if you've fixed it or not ...
Manual trans: make sure clutch is disengaged while shift the transfer case and (1) you are not turning but going straight and (2) you are not going over 45 mph.
Auto transmission: shift to neutral before shifting into 4X4 and (1) and (2) are the same as for the manual trans.
If that doesn't help, the transfer case may be worn out.
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Budd Cochran

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