Offroad-Express

My trusty 91surf 2.4diesil while in 2wd clunks mid range in 1st gear,while this happens the 4wd dash light lights up and goes out again,yet it doesn't fully engage into 4wd.- This does not happen in while actualy in 4wd, have had a single stage clutch replaced recently which has had no change to the problem, I have talked to a 4wd drive specialist who tended to believe that this was likley to be a electrical fault causing the 4wd drive system to want to click in while the engine is under maximum load, ie take of in 1st gear [in 2wd][either in terms of torqe or increase of voltage]. ANY ideas/ theories/experinces would be great as I don't want to have to walk her out into a paddock and shoot her ! Thanks Dennis..

Manual or automatic hubs

Kent

auto...

Now get this, after a month of 'clunking' one of the many radiator hoses[deep down and differcult of course] blew and spewed antifreeze everywhere, from the engine bay to halfway down the chaisis. This stoppped the cursed clunking completely, I mean instantly. So I'm guessing that the 4x4 relay that is attached to the axle was shorting and trying in engage the 4x4, which got a blast out from the water and corrisve paint destoying antifreeze which cleared out what ever gunge was causing the short. Just a theory as its not easy to figure with out doing a expensive autopsy....What do you think ?