Ill go test right now then.. Thank you..

 

Ok now I am confused.. It works.. The shift fork shifts smoothly from 4x4 to 2wd, and vise versa.. the gear moved smoothly.. both lines have vacuum.. So, I know my transfer case works, and my actuator works, and that the gear can shift, and the fork shifts... There is vacuum, yet, I still cannot get it to work... OMG. I currently have all different size tires, so I cannot test drive it, however.. before It had 265/75/16 on the front, and 285/75/16 on the back... It was like that when I got it.. Would this cause it to absolutely NOT go into four wheel drive? I can get it in now and then, but the truck shakes like mad, and the TC whines loud.. I though as stated before, my axles were stuck engaged.. but obviously not here.. I dunno what on earth.. =\

 

How's the alignment of the axle shafts?

having smaller tires in front, and putting it in 4x4 is more likely to trash the t-case, than anything else. The strange noises really don't surprise me...... All four tires MUST be the same size.

If everything works while you have it in hand.... it should work when installed as well. Make sure the fork is going into the groove on the collar that slides to lock the axles halves together. I bet the little nylon 'feet' are gone from the shift fork though.

 

+1.... As far as the vac goes though. You don't have vacuum on both lines at the same time do you? And I bet you are not using a gauge to verify how much vacuum.

 

Alignment looks good, I dont know 100% for sure, I know the collar goes over both axles without any issues.. if, that helps.. There is only Vacuum in one side at a time, I tested that before I tested the fork, and the fork actually looks fairly new.. The nylon feet are perfect.. I wonder if they didnt replace this before I got it, and missed the groove in the collar? Hnn.. Zman, No, I didnt use a guage.. I don't have one to use.. All I know is I hooked the vacuum motor up to the indicator and vacuum lines, but left the fork out of the shaft, and had my husband shift it in and out of 4x4, and the fork moved back and forth, in the right position (left for 4x4, right for 2wd) Just like it should..

 

Sounds like things are working as they should be then. Put it back together, makes sure the fork engages the collar properly, and give it a shot. Bear in mind, engagement/disengagement is NOT instantaneous. Mine takes a few seconds to come in/out of 4wd, and I gotta be moving. Turn the wheel side to side a bit as well. See how it works.

 

Is it safe to give it another try now? Like I said it came with smaller tires on the front.. but one of the back ones went flat, so the spare is there, and its different from all of them, and then the driverside front busted loose and is destroyed, so all four tires at this moment are different until I get four new ones.. (It doesnt get drove but a few miles gravel as of right now).. Or should I wait? My Dakota took a bit to engage and disengage to.. of course it was electronic and you could here it click till it was engaged or disengaged.. Ill put it back together piece by piece and double check everything.. Will let ya'll know.. Thanks for helpin me out these past couple months.. I appreciate it more than ya'll know!

 

So long as they are all the same size, it's cool. If they are 'close', on gravel should be ok for a test, just don't drive it far in 4wd.

 

Since two are spares, about as close as they get is 75/16.. They range from 235-245-265-285.. LOL! I have a couple the same I just need to go have the rims switched.. Think I will wait till thats done.. Just havent had the time to go buy new tires.. After I get them changed I will test teh 4wd and Let you know..

 

Okay, I have all four same tires on, will test tomorrow.. I talked to the local shop and he said it sounds to him like the vacuum lines where backwards.. I didnt know the transfer case would engage in 4x4, but the axle would disengage, and vise versa if the lines where backwards? Anyway, when I tested them, it was after I pulled the lines loose and put them back on, so it is a possible they were.. Requardless, I am going to double check everything and put it back and test it tomorrow.. I will let you all know as soon as its done.. Here's hoping!!