I cannot figure out what is wrong with my truck. ive got an 04 F-150 with the 5.4. I was driving and I began to notice a grinding noise from the front end. It sounded like an actuator trying to engage. I bypassed the solenoid to disable the four wheel drive, It still made a noise but stopped when i put it into 4HI. The solenoid has been bypassed so it cannot be the Actuators. I'm Beginning to think the transfer case shift motor is bad. I currently have the solenoid bypassed and the transfer case in 4HI. This stops the grinding noise but I am stumped.

 

https://www.f150online.com/forums/ar...then-some.html

 

Reservoir and/or check valves...

 

You say it cannot be the actuator.

That leaves bearing noise.