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Ineed to know what kind of shifting system you have. Is it a shift lever or a push button systemThe fact that it works sometimes is a good sign. So this means its not completely broken and could be a simple adjustment
Check the fuse to the 4x4, if the fuse is good then check the 4x4
electric motor actuator on the transfer case. You should hear it work
from 2wd, 4hi to 4low and back to 2wd with the push of the switch. if
you don't hear it working then check the wire harness at the actuator
motor, look for any damages like corrosion or cracked wire connector
clips. If the 4x4 actuator is working on the transfer case, then the
front hub 4x4 actuator may have gone bad and that's located on the
front differential. It's common for the clip there to corrode and break
and is an easy fix with a new collar pin, at worst it's the diaphragm
on the vacuum actuator that is located under the battery tray. There is
a vacuum switch on the top of the transfer case, driver side but when
that fails, your front hub stay's locked in the on position. Good luck
and keep me posted and hope it's a simple fuse that has gone bad. You
can pick up all these parts at Auto Zone or Parts Source and they will
have the step by step instructions for you to get the job done with
you need to pull the switch out of the dash and look behind the swict hfor the actuator, chances are the stud that touchs the actual relay is broken use a pen or something slender and long to push it to the desiref position, other than thats go to a junk yard and look for that switch, should just pop out with a lil prying..
just had simular prob.. check front diff for fluids, check actuator, and also there is a switch on the top of your transfer case . all else fails, have vehi. on jack stands (all 4 tires off the ground) start, hold brake, push button,and have someone under to watch cable ect. (""do not put in gear or give gas while doing this"")