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..
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 ?