Remove transfer case shield. Remove clamp on boot
where front drive shaft meets transfer case. use a flat
screwdriver to pry free end up and release clamp. (you need a special clamp tool to reinstall clamp )
Remove 4 bolts at differential end that hold U joint Retainers to yoke. Slide drive shaft to rear enough to clear yoke. then let drive shaft drop so it clears differential and slide forward until it come off transfer case shaft.
SOURCE: front axle - front drive shaft Toyota tacoma 1998 4x4
more than like have a broken axle shaft, un hook the rear drive shaft and put it in 4wd if it wont move then you know you got a broken axle shaft or spider gears broke in the pumpkin
SOURCE: i have a 97 chevy 1500 4x4 and the front wheel
Had the very same problem . It is the actuator pod under the battery tray. You have to remove the battery and battery tray and it is located under it. 3 screwsand one vaccum line. Part is about 50$ at the parts house
SOURCE: Chevy Tahoe 2001
Place vehicle in 4wd (high or low). This will hold the front drive shaft still for the rest of the test. Jack up the front end of the vehicle. Remove the actuator. Have a buddy spin the right front wheel while you use a long punch or screwdriver to try to manually engage the diff. The left front wheel should spin in the other direction if the diff is good. Also before you check the diff you need to grab the front driveshaft and make sure it is locked, If it spins freely when the truck is in park and in 4wd with the front end raised then problem is in transfer case. If you can't make the diff engage manually with punch then the problem is in the diff. If front diff engages manually then the problem is the actuator. Hope this helps..
SOURCE: 4x4 won't engage. 2001 Ford F-150. front axle actuator is new
If you know that the actuator on the front of the truck is good check the wiring for any breaks. If it is anything like my truck the wires on the front actuator should run to a switch on the top of the t-case. If you cant find a break in the wires running to the t-case your problem is most likely the switch.
SOURCE: how do i remove a transfer case motor from a 2003
you have to remove both to get the tranfer cas out. it just bolt on the the back of the transmission.
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