Actuator wanting to engage on its own transfer case

Is this a push button 4x4 system? If so, the push button switches themselves short out sometimes and act like they have a mind of their own. Unhook the switch and see if it does better. Let us know.

Well it has been a long time since I did any work on one of those. If I remember correctly, the pin that holds the selector in place can get a little loose, causing the lever to easily slide back and forth. Try taking the rubber boot around the shifter off and checking and rechecking the tightness of everything.

Do you mean the transfer case tries to engage or the front axle actuator?

To see if it is electrical or mechanical, pull the 4WD fuse (no 24 in the I/P box) That will cut power to the switch and front actuator. If the problem goes away it is either the switch on the top left of the T-case which is turning the front actuator on for a couple seconds.

Or the linkage is loose.

Okay, mechanical it is.

Do you have any gravel roads or wet grass nearby? Something with low friction? If so get on that surface and shift into 4 high, see if you hear the same noise then.

Also check the U joints, a dry or stiff one can make noises and cause other parts to make noises as well.

Drive line noise can be a bear to trace. I have spent a lot of time tracking down noises with various tools. I use a chassis ear a lot. I have also have a few cheap digital recorders that I added clips on.

Do you think you could record it and post it online so we can hear it?