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I had a similar issue a few weeks ago with my XTZ and took it into the shop. The front differential was cracked and needed to be replaced.
 

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Are you engaging the 4wd stopped or while moving? I thought that you needed to be completely stopped to engage the 4wd and it was ok to be moving while disengaging????
 

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Discussion Starter #7

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Discussion Starter #8
This is what the ops manual says


To select 2WD, depress the bottom of
the switch. To select 4WD, move the
switch to the middle position. To
engage the differential lock, slide the
switch latch slightly downward while​
pressing the top of the switch forward

Do not attempt to either engage or
disengage the front differential​
while the vehicle is moving.

They way I understand the above warning it is talking about the diff lock????





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I have never had that problem yet Seth.Mine had made a small bang sometimes when I flip the 4x4 switch while driving under a slight load.I am sure that that is it engaging the front diff though.Sounds like it is worth a look.

I can hear the solenoid engage and disengage, and when it does this it is very quiet. If it was going in and out while driving the solenoid is soft and quiet so I tend to think it is something else.



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