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If the actuator is not working and you need to engage your 4x4 to get home, you can manually lock in your 4x4 system using the front axle's manual locking hubs (assuming your vehicle has manual locking hubs). Here are the steps to manually lock in your 4x4 system:
Locate the manual locking hubs on the front wheels of your vehicle. They are typically located at the center of the wheel hub, and will have a dial or lever that you can turn or pull to engage the hub.
Make sure your vehicle is in neutral, with the parking brake engaged.
Turn the dial or lever on each manual locking hub to the "lock" position. This will physically engage the front axle, allowing power to be transferred to the front wheels.
Engage your 4x4 by shifting the transfer case lever into the appropriate 4x4 mode (4-Hi or 4-Lo).
Test your 4x4 by driving slowly in a straight line. If you hear any grinding or feel any vibrations, stop immediately and check your manual locking hubs and 4x4 system.
It's important to note that driving in 4x4 mode on dry pavement can cause damage to your drivetrain, so be sure to disengage your 4x4 system and unlock your manual locking hubs once you're back on solid ground.
Being an older 4x4 you will need to manually engage the hubs aswell as move the shifter into 4x4. To engage the hubs you will need to turn the switches on the hub/rim's themselves.
This depends on what system you have installed in your truck. If you have push button 4x4 with auto locking hubs then you would put your vehicle in neutral and press the 4x4 button. You then drive froward about 10 feet and the auto locking hubs should then be engaged.
If you do not have push button control and you have a gear shifter which controls the transfer case you would push the level in 4x4 hi or low depending on what you want (while in neutral) then drive forward about ten feet so the hubs lock. If you have manual locking hubs you need to manually engage the hubs before you put it in 4x4 mode,
There are two parts to the auto-locking hubs. Inner and outer. Both of them have small tabs on each of the 'cams'. Chances are, they are broken off on the outer hub. When you clean them up real good, you can see them. I believe when the axles turn the outer hub, the inner and outer cams push against spring pressure and lock the unit to the wheel hub. These hubs will break when engaged at higher speeds, especially on a dry tar road.
I found a website that explaned that you can remove the hub and dust cover, inside is a spring which holds the hub out, removing this spring and replacing the rubber dust cover and hub will lock your front hubs in continious. as is done on later models, This has worked for my 98 4wd
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