SOURCE: 1993 jeep grand cherokee laredo 4 wheel drive
I'm not absolutely sure on the tire size for the jeep itself, but I think they are 225/65/R15's. Not absolutely sure.
As for the noise, from your explanation, it sounds like the transfer case is under a heavy bind. Take it off of the road in some grass or dirt and then move it forward a few feet then simply hit reverse. Don't move much maybe an inch and it may release the bind. Once you get the bind off the transfer case, it should slip out of 4wd, unless there is damage in the case/shifter itself.
When operating four wheel drives, with tires of different sizes it causes extreme stress on the gearing in the transfer case. Larger tires don't turn the axles as much as smaller tires. So, this causes stress in the driveline as the front is actually turning slower then the rear. In turn, this will put so much pressure on the gears that it could cause damage and the shifting mechanism will not work correctly to pull it out of 4wd engagement.
Try those ideas, and see if you can get it out of 4WD. Definitely put four tires on the jeep that are all the same size. This will keep you from having excessive stress on the transfer case and gearing therein.
I hope this helps out buddy.
SOURCE: clunk in front end when take off or stop
sounds like there is brake equip in rear brke not installed properly
SOURCE: 4 wheel drive (auto locking hubs) seems to be trying to engage.
I had the same thing happen. The automatic locking hubs are faulty, causing one or both hubs to try to engage or disengage onto the front driveshaft. This makes the clicking noise and loud clunking that you hear. You may notice your steering pulling to one side of the road,because one hub is locked in. Replace the automatic hubs with new ones, do not try to fix the old ones. I liked the
convience of automatic hubs but replaced mine with manual hubs, there just way more reliable.
SOURCE: Noise in front end 2002 zr2 blazer
Two things maybe your problem:1 .Front axle actuator to engage 4wd is not releasing. 2. Front axle u-joint needs replacing. Lift car on jacks with front end off ground. Then spin tires by hand as fast as you can and see if you hear the noise and where it is coming from ( spin in both directions).
Testimonial: "Thank you! It was the actuator that was causing the problem."
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