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.
Tolerance cannot be legislated, demanded
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