Long story short... I had to use my 4WD this weekend and when I disengaged it there was a loud grating sound from under the truck and the indicator light never went off. I crawled under the truck and pulled the sending unit from the CAD housing and pushed on the pin that slides the collar back and forth and the thing wouldn't budge with the truck running. If I turned the truck off I could push it, disengage the collar, just fine. So I'm guessing for what ever reason there is a constant vacuum coming from the transfer case. Any suggestions on where to start? Oh I should also mention that with the stick in 2hi there is no power going to the front wheels. 4hi and 4lo have power. Thanks in advance guys.

Brandon

 

try to determine whether your problem is in the transfer case or the CAD. for example, if you LABEL and then disconnect and plug the vac lines at the cad, then you can shift t-case in/out of all settings and see if you are getting noise/grinding. a common problem in the t-case is a broken snap ring that lets everything get all out of whack. if t-case ok, then investigate cad. use pb-blaster or wd-40 on the little cad bolts and take it apart and see what's going on. (a small amt of oil will drain out so have a pan under it.) try hard not to break the cad cover bolts. they're little. there's not a lot to the cad.
http://www.dodgeram.org/tech/repair/..._engagment.htm