Have read and tried the fixes on this forum have found a lot of great information but can't seem to fix a 4x4 issue.So far I have replaced all vacuum lines started truck left running took out battery actuator is sucking in fine cable is moving about 1/2 inch when put in 4hi.Had truck on a lift when put in 4hi,4lo front driveshaft spins wheels do not.This is a 3 button shift all buttons light as normal looking for suggestions on what to try next.This is my first time posting am a new member just bought truck a month ago hope I gave enough information.Thanks

 

1/2" of cable travel is on the low side for proper engagement. Typically travel is between 1/2" and 3/4" for full engagement of the disconnect in the front axle.

If you cannot manually pull the cable more than 1/2" while slowly rotating the front passenger wheel, then I would suspect an issue with the engagement mechanism in the front axle which would require pulling the passenger side extension housing to access. I have posted pictures of what that all looks like one of the 4wd related tech articles and I am sure there are videos on Youtube.

 

Thanks will give this a try,should I have truck running and in 4hi when I try to pull cable and rotate the tire manually?

 

The truck doesn't need to be running. Having the transfer case in 4HI with only the passenger front tire off the ground is preferred as this will result in the front driveshaft being locked in at the transfer case.

If the front axle disconnect properly engages, the front passenger wheel would no longer be able to turn in this scenario.

If you feel it slipping over regardless of how much tension you put on the cable manually, then you have problems internal to the front axle that need to be addressed. The most common issue is that the front axle disconnect collar has likely been in a partially engaged position due to a froze up vacuum switch on the transfer case which has resulted in rounded off teeth on both the collar and the drive flange located on the inside end of the passenger side extension axle shaft. This is the condition shown in the 4wd Front Axle Clicking When in 2HI - Goes Away When 4HI/4LO thread.

 

Pulled cable manually front wheel locks could the spring on acuator cable be bad? It locks in where slit is seems pretty rusty don't if that means anything. Thanks

 

Am also wondering what size vacuum hoses are coming from vacuum switch.Appears to be 2 of one size 3rd one is larger anyone know proper sizes? Thanks

 

Update,after replacing all of the vacuum lines raised front passenger tire started truck put in 4hi and could still spin tire.Talked to my mechanic today he suggested driving it and put in 4hi and see if it engages.Unbelievable my 4 wheel drive actually works.Thanks to all the information I got on this forum on to the next project