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It sounds like the transfer case might have been stuck in 4wd and it popped out. This happens sometimes if there is a load on the transfer case when you shift in or our of 4wd. Does it seem like the 4wd is disengaged properly now?
Will it go back into 4wd properly?
You can change the fluid in the transfer case and front differential fairly easily. This might help. You might also need to have the transfer case shift motor inspected as well if the noise doesn't subside.
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