Hi, i have strange noise comming from front diff. It all started like this. The vehicle did not switch to 4x4 because the owner before me tried to get 4x4 without stopping completely. after some research i replaced the Shift fork because it had broken teeth. I took the fork to the far right and pulled the car to 4x2 mode and completed the installation. But after that, when I leave the vehicle in 4x2 mode, I hear a knocking sound at completely meaningless times while driving on the road. When I put it in 4x4 mode, this sound does not come. I tried all mods and I can switch to all of them without any problem. Has anyone had this Strage noise before? Thank you.

[2015 Z Force 800 53/Trail EPS]

Sounds like when only when it's "free-wheeling" that this condition exists. I would check the play in the pinion shaft thinking maybe a bearing is failing and while there I would inspect the front drive line's u-joints and carrier bearings as well as the play in the splines. If all that seems OK, then look for play in the CV joints. Have the wheels pointing straight and don't jack it up. This all assumes you placed that new fork in the right place on the slide and the actuator is actually moving it to the far right so it will be 100% disengaged. You can pull the actuator straight out and see if it is actually within an 1/8" all the way to the right in 2wd. If you jack it up high enough you won't have to drain the oil. I say this because any action by the operator that causes broken teeth on the fork slide "can" also cause internal damage on the actuator..as in stripped/broken teeth.

thank you i will do what you said