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    Default Transfer case noise

    Hello all, new to this forum but not new to working on vehicles of all sorts.
    Current fleet includes 2007 HHR, 2002 Malibu, 1966 Chevelle SS, 1984 Chev 3/4 4x4, 1995 Pontiac Transport, 1968 Ford Bronco and the curent problem child a 2002 GMC Jimmy.
    The Jimmy just had the motor replaced (I bought it with the motor failing) and during the swap I visibly damaged the front diff actuator cable. After the motor was running I tried the 4x4 (4 button electronic NP8 option) and everthing worked. Didn't like the look of the kinked cable so I replaced it.
    At first startup the service 4x4 light went on and hasn't been off since and the transfer case is locked in 4x4. During the actuator cable swap I dissconnected the cable sensor and re-attached without incident.
    Now when the 2HI position is requested I can hear the transfer case motor running and I get some clunking on the RH kickpad but the 4x4 light flashs back on and the front driveshaft is engaged but the front actuator has pulled the RH front wheel out and it is dissengaged.
    Tried removing the battery for a day (in the hope of clearing the transmission codes if any) then re-attaching and still get the same condition. Have an OBD11 reader and cleared one misfire code (old spark wires = replaced) but no other codes showing via reader.

    HELP!
    Last edited by guzjimmy; 11-18-2012 at 10:12 AM.

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