so, I've got a 96 Ram that is sticking in 4x4 mode even though I've moved the transfer case shifter out of 4x4. The light on the dash goes out, but the front axle isn't letting go. It's been suggested to me that the clutch packs in the front axle are sticking... does that sound plausible? It's the Dana 60 front axle if that makes a difference. Is that something that a shop could fix in 1 day? I understand they'd have to open up the front axle housing to deal with it. Reason I know it's not releasing is because you can feel the binding in the front end when making a sharp turn on pavement. The usual feeling you get when turning with it engaged in 4x4 on pavement...

 

No clutches in the front axle. The passenger side axle is two-piece, with a collar that gets slid over to lock them together. Its all vacuum powered, so, even a minor vacuum leak can give you delayed/no action there. First thing to check is, ARE you getting vacuum to the cad? (central axle disconnect.) You will find that on the passenger side axle tube, two lines going to it. In 2wd, outboard line should have vacuum, in 4x4, inboard line should have vacuum. It might be an easy fix.

Have a look here for how it works.

 

ok, read through all that and it makes sense... should the vacuum be enough that if I unhook the line I will be able to feel the pressure on the end of the line. Sorry for the questions, but I'm a carpenter, not a mechanic, lol. I will take it to a friend of mine who is a very good backyard mechanic to help me with everything. From reading the info in that link you posted, it's either the vacuum at the axle, or the plunger sticking in the switch which is mounted to the transfer case. Sounds like that is a relatively easy thing to unscrew and clean. Am I correct in assuming that?
Thx.

 

Yes. You should get full manifold vacuum there. If it's less at the CAD than at the intake manifold a few seconds after clunking the transfer case shifter, you've got a leak somewhere.

In that case, ignore what I just said. I'm a computer programmer.

 

ok... one more question before I get set to tackle this this weekend (it's a 3 day weekend up here in Canada) Does the fact that the 4x4 indicator light goes out indicate if it's the plunger in the switch at the transfer case or the control motor on the axle?

 

Actuator doesn't need to move far to turn the light off, does have to move pretty good to completely disengage though. Check vacuum at the actuator. If you have strong vacuum, you have an internal problem. (on the axle) But, keep in mind, a vacuum leak will give you the same problems.