SunlitComet
OBS Jedi-Do Good
Your actuator seems to work as the feedback sensor sees it and lights up you 4hi continuously. However the shift fork could still be broken in the front axle. the test for the front ds spinning will on be accurate to some extent if you test it while the front actuator is electrically disconnected if vehicle is on the ground. if the front actuator is engaged the front ds would spin with vehicle motion regardless of t-case mode. you really need to get all four wheel wheels in the air with nothing underneath them to test for the various mechanical outputs. as for the noise if verified it coming from the t-case it needs to be repaired plain and simple. also there is no hub work involved as the hubs do not lock at all. it is strictly a axle shaft connection to the wheels.