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I had the same problem last year on my 04 but at 120K miles (Great Truck) it is far from out of warranty. Makes almost a grinding noise when cold as moisture can freeze in the solenoid and not keep the 4WD hub fully diengaged ...
It went away after a short bit but I'm keeping an eye on it for happening this year. I've had no 4WD issues at all with it.
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