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Don't know the vehicle specifically, but if you've replaced all the components that are run from this fuse then the only thing left is the wiring loom itself. Maybe some foreign object (rock or stick) has damaged the wiring and the wire in question is shorting to earth somewhere in the loom. To check this all you need to do is work backwards from the furthest point. That is disconnect the actuator on the transfer case and turn the switch on. Then disconnect the sensors and turn the switch on, disconnect the actuator on the front diff and turn the switch on. If after everything is disconnected the fuse still blows, then it MUST be the wiring loom. Have you done any " home handyman" wiring under the dash? maybe you nicked a wire by accident? It's a fiddly process, but give it time and you'll get there.
Sorry no idea here without as look to see whats wrong ,could very well be a electric solonoid switch that locks up a dog clutch but 4x4 is not something i do very often .Most i see are permanant 4x4 isnt this truck permanant rear wheel drive anyway and you lock in the front diff by means of a solonoid or a cable
Couple things to check, transfer case and front diff fluids, make sure
no wires are bare or shorting together on either transfer case or front
diff, just to eliminate the easy stuff first. I would also check the connectors at the ECM and TCM just to make sure
they are secure and tight.
That truck uses a heating element in the hubs to expand the metal and engage the hubs. Manual aftermarket kits are available what replace this questionable system. Check with your parts store or 4x4 shop.
By the way, if that happens again (Same thing happened to me) It was inside the front diff. That vacuum actuator that sits on the passenger side that has a vacuum hose going up to it has a built in cable that plugs into the front diff. There are little springs that go bad and there is no tension on the cable. It retracts but doesn't engage the axle.
It's 3 bolts, then pry it open just enough to get access to the spring that holds the cable together. ;) That's how I fixed my problem permanently
look on the passenger side up about 6 inches from the bottom of the rearend.. it takes either a big allen wrench or a 3/8 socket..take that plug out and stick a piece of wire down in there or your little finger to test where level is . thanks jerry holler if you have more
there should be a front diff lock actuator right in the side of the front differental that has an electrical connector that u have to unconnect and unscrew the actuator and replace. this part will run you about $100 and should take about 10 minutes to install. or another alternative is they have a manual kit out that replaces the actuator and it is a pull cable instead of an electrical job.