If your sure that the actuator is working then try this test. Put it
into 4WD. Trans in PARK, Now jack up the RIGHT front tire so it is off
the ground. Try to rotate it.
If it rotates you have a problem with the cable,the shift fork or the
sleeve inside the disconnect, or possibly damage in the front
differential itself. To figure out if it is the shift fork or sleeve you
will need to take it apart.
The cable is only held into the shift fork with a small wire clip. That
clip may have broken. Or the cable itself may be bad. Not real hard to
check/change if it is the problem. First release the clip that holds it
to the vacuum actuator so the end is free. Then you need to jack up the
front end. Secure it with jack stands.
Now you need to decide if you want to just check the cable OR if your
going to check and replace it yourself?
To just check and see if it is connected you can unscrew the nut that
screws into the shift housing and see if the cable is still connected
inside. If not then look at the end and see if it is broken or worn. If
it is connected and doesn't pull out then the problem is farther in.
If the cable isn't connected and it appears OK then the clip is probably
bad. Dealer part.
Then remove the bolts that hold the shift cable housing to the axle.
Pull the cable/housing out and you will find the clip. Replace it and
reinstall the housing, bolts get torqued to 36 ft.lb. Then slide the
cable end into the hole and push it in until you feel it snap into
place. Then screw the housing nut back in (I put a small amount of never
seize on it just in case) Reconnect the upper end of the cable and test it.
For pictures and instructions on the shift cable.
It is nothing special. Just an open differential with the left axle
split for the selector sleeve. The catch is that there is no cover to
pull so you can look inside. However you can also pull it out to work on
it and still be able to drive the vehicle.
Shows a breakdown image.
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