We switched the hoses and checked it.. still the same.. =\ In fact I drove it that way to double check.. Nothing. Zman, I will give this a good look through tomorrow.. I havent replaced them yet, I have the truck up to replace the u joints now, but its not going my way.. I pulled everything out, removed the bolts on the back of the knuckle, and the hub is NOT budging.. Ive lubricated it, put the bolts back in and tapped it every which way.. this sucker just wont let go. Ugh!

 

when i replaced the hubs on my 4x4, I had to use my slide hammer to get them off

 

Hhmm.. I dont have one of those.. but Someone I know might. Thanks a bunch!

 

You can also use a piece of metal the correct thickness/length and wedge it between the head of the bolt and the steering knuckle, and use the power steering to push it out. A little at a time on each bolt. Be careful the the metal doesn't shoot out and nail some one.

 

Ok, late as usual.. I found a broken vacum line, which done no good to fix, also replaced the u joint in the drive shaft and noticed the drive shaft turns freely (When disconnected from the diff) in 2wd and Nuetral, and locks in 4x4 in 4wh and 4wl.. So, the transfer case is doing its job.. However, The CAD does, not, move! Im going to take the sucker off, today, and inspect.. Could this be the actuator, if not internal damage? I actually got it to "TRY" to disengage three days ago, the light went out, but you could hear this god aweful spinning noise.. when I reached under to turn the drive shaft, it turned just enough to catch the diff, and the 4x4 light came back on, and the sound went away.. Ugh! Slowly pin pointing this.. I have been working on repairing damage done when the driver side front tire flew off and totalled a car a few weeks back.. So I havent had time to work on 4x4

 

Verify vacuum on the correct ports for which drive mode you are in. Sounds like you aren't getting vacuum to the disengage side of the actuator. (outboard port.)

 

I agree with HeyYou, no or not enough vacuum on the side that pulls it back into 2wd. I was having the same problem (and still am) I unplugged the vacuum lines and disengaged the 4x4 and haven't figured out yet why I have no vacuum on the one side. So when I do I'll let you know, if you figure out why you don't, please do the same...

 

Ok.. As stated, I have never touched a 4x4 before.. Im loosing it.. I thought, the whole big outside of the sleeve that houses the shift fork moved.. So I was thinkin it was NOT moving at all, I pulled it open, and the little shift fork, INSIDE, Moves, and so goes the gear.. It engages and disengages when pushed by hand, so it is not froze up. Can I test my vacuum lines with the cad apart, or should I put it back together.. Im going to inspect the bearing real quick anyway..

 

Ok.. Bearings are fine.. I need someone to explain this to me though.. the shift fork moves up and down, and the gear goes side to side...?? Is this right? I stuck it up there and moved the shift fork to test if it moved the gear and it does not, it just smacks it.. (Unless I am missing something here).. But the gear moves when I push it by hand, easily.

 

Yes you can test the vacuum with it off. Just unplug the vacuum line (which should have already) and start the truck. With it in 2wd you can feel vacuum coming out of one line, with it in 4wd you should feel it coming out of the opposite line, just use your fingers over the end and you'll be fine.