So I pulled the actuator from the top of the transfer case to check to see if the ball was frozen stuck or rusted... And it's not. But now I can't for the ALL HELL of me get the thing threaded back in. WTF...???

 

I've finally got it in. The actuator is pitched foward, meaning the three vacuum lines and actuator itself will be on an angle facing towards the front of the vehicle not straight up and down. What a ****ing PITA.

 

Are you talking about the Transfer Case Vacuum Switch??

When you say Actuator, this usually means the Front Axle Actuator that is located under the battery tray. It is connected to a cable that locks in the front axle..

If you are talking about the Transfer Case Switch, make sure the connector goes on correctly. If not, the Front Axle will not engage. The connector is keyed.

 

Thanks. It (vacuum switch) went in fine once it was angled forward. Cable actuator under the battery was the culprit. Very easy mechanism to change. All is well again in 4x4 world. Even the check engine light is gone prob from vacuum being bad. Thumbs up.