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under the battery there is a diaphram that has a cable that runs to the front differential, if you can squeeze in there and pull on that cable and make it work you would likely have a vacuum problem... they come disconnected from the back of the intake manifold some times, and have seen the vacuum lines come loose at the transfer case.. anyway there is a starting point!
Just to verify, have you removed the hubs and verified they move freely in either direction? and that the vaccuum diaprhagm inside the hub is working? By stating the vaccuum system, you do have AUTO hubs correct? I have fixed these problems many a times and found it is usually the auto hub assembly itself is not properly operating.
so the front driveshaft turns in 4 low? or you just feeling gear reduction in 4 low?if the front drive shaft will not turn in 4 or 4low then suspect a shift fork broken. when i say turn i mean under engine power.
Hi, Do you have auto locking hubs on the front wheels, or manual locking hubs? If you have auto locking hubs chances are they are not engaging properly and will need to be removed and spline sets checked for broken teeth on locking hub and locking shaft. If you have manual locking hubs then check that they are firm when turning to engage them in the lock position.If they are light when engaging them to the lock position then they my have broken/worn out the locking hub and spline. Also check that the engaging spring inside the hub has enough tension to engage the hubs they may be broken. If the hub are all ok then you have a problem in the transfer box, where the 4WD lever is not meshing the transfer box properly. Hope this helps, let me know how you get on.
take actuator back out then plug connector back on it but leave it out of axle now turn key on and shift into 4 wheel drive if actuator moves out then problem in in front axle u need to pull right half of axle apart if it doesnt move then it electrial problem to actuator check fuse
First of all try checking your fuse box and make sure the 4X4 fuse is
still good. If the fuse is good, move the shift lever for the 4X4 on
the floor into 4 high, then get a friend to watch underneath when you
move the vehicle a little bit to see if the front driveshaft is
turning. If the front shaft going to your differential is turning the
problem is probably the electric actuator on the differential.
Three probable issues; 1-The transfer case is low or out of fluid. 2-The drive shaft may be out of alignment due to worn front or back U joints (thus the clunk on shift) 3-the shift lever is out of alignment with the shift mechanism on the transmission housing.