page 2461 of the service manual download (merry christmas thread) says its 1 1/16.
trying to post it...
aw this sucks. i open a big pdf, and save one page as a small pdf, but can't upload the small pdf becuase its too big. can't upload a pdf to photobucket. can't open a pdf in irfanview. standy by.

 

I got it out with the big-*** channel locks that slipped and broke it :P. The plunger is definitely sticky. Time to look around for a new one.

 

http://quad4x4.com/Dodge%20Transfer%20Case%20Parts.htm

 

Alright, I have one on order. For now I guess I have a 2wd pickup with the "benefit" of the extra weight of a 4wd. I have to admit that 2wd low range is kinda fun, albeit a bit hard on the tires:P

I'll post back when I get it replaced as to whether it fixed it or not. It was definitely stuck so I'm sure it will.

Thanks guys!

 

oops. too late
http://cgi.ebay.com/ebaymotors/01-20...QQcmdZViewItem

 

I got the new part from O'Reilly today. Dorman Help! brand, appeared to be a perfect fit. It all went back together fine... but when I tested it out the axle locked in 2wd and unlocked in 4wd.

Grrrr...

So I just swapped the red and black vacuum lines around and I'm back in business. Thanks all for your help, and beware the Dorman 4wd switch-- it must have been made in Australia :P

 

aahhh. another satisfied customer.

 

Just spray some P Blaster in the vacuum nipples on the switch, it will free it up. Worked fine on mine.

 

i did not know it was that easy, the reason i say that is because i have the 4wd light on my dash on all the time, it does not go out at all, ever. but now that i know this. it will be fixed. and yes that line that was "damaged"... (or looks to be burnt if im not mistaken) is from the cat, it runs under the cat and the best bet it to use the rubber lines like you did, and replace both, and then rerun them in differant places like behind the crossmember and in front of the cat to stop this from happening

 

I would have but my stupid *** broke off 3 of the nipples when I was taking the old one out :P

My wife is worried... she only has 2 nipples.