4 wheel drive kicking in and out

[smoken]

just wanted to know if i'm on right track clunking noise or sudden jerk felt
like tooth missing on diff pulled back drive shaft went for drive same pulled front axles and drive shaft sudden jerk pop felt like under gas pedal foot
no spcefic time or speed up hill flat ground pulled transfer case took apart only thing i found wavy spring broke everything else looked good put new wavy spring in reassembled install drive same thing like 4wd trying to kick in but pops out 4405 bw 1997 explorer 4.0 sohc automatic auto 4hi 4lo
think they call this control trac not sure was thinking about the brown wire mod i've been reading about i was going to cut it at the case drill hole run 2
wires thru floor hook too on off switch does anyone think this will help or tell me my next direction would also like to say i read alot of the forums and you all seem like a great bunch of hands thanks for evrything smoken

 

[gijoecam]

First tip: Use punctuation. Reading that was downright painful!!

Second tip: Unplug the transfer case and take it for a drive. If the noises disappear, it's an electrical issue. If they persist, it's a mechanical issue.

We'll go from there.

 

[smoken]

I did second tip unpluged TC ran out fine. How long can I drive like this withou hurting anything? I need to start checking into sensors and whatever
electrical could cause this. any info appreciated