Thanks for the responses to my earlier posts.
So far I have replaced the vacuum lines, transfer case vacuum switch
and the vacuum actuator (which, btw, is NOW an aftermarket item
available at NAPA, 2 days after I paid $85 for it at dealer-only price
lol)... put it up on stands and verified that the transfer case is
working (front drive shaft is turning, front axle is not).
In the process of changing the actuator (which needed to be replaced
due to torn diaphragm), I noticed that the front axle shift cable
pulls very hard... it seems to drop into place, but takes a lot more
pull-pressure than that vacuum actuator will provide...
the plan now is to replace the shift cable and the front axle shift
assembly (fork, washers and springs)... since all of these parts are
approx. $100, I figure to kill all the birds with the one stone so to
speak and just replace the entire assembly...
Can anyone tell me what kind of problems to anticipate when doing
this? What should I look for in the fork/shift assembly when taking it
apart/reassembling? How easily should the shift cable pull the thing
Comments/Hints/Suggestions very much appreciated from you folks!