front diff not locking before and after installing a posi lok the t case is working was should only thing I can think of is that its something inside the front diff that is broke

 

Front vacuum actuator working?

 

Replaced with a posi lok kit

 

are you sure the cable is pulling properly?

 

Try rolling a bit while pulling the cable

 

+1^^^ also make sure that crappy little spring clip is engaged at the bottom of the cable.

 

Yea, what I meant... No more late night posting for me....

 

the seals in the 4WD actuator are probably gone, very common problem expecially if you had a leaky battery becuase its located under the battery. pop the battery out and see if you have vaccum pressure in the actuator and make sure the rubber is ripped. & then and see if the cable is seized or not.. if everything looks fine, but there is no vaccum pressure its the switch on the side of the transfer case, cheap fix but a pain in the A$$. Other than that I could only think that maybe the cable isn't adjusted properly on the side of front diff.. when you took the diff out and removed the cable maybe now it needs re-adjusted.. also there is a shift fork in the front of that diff and if you put it in backwards it wont engage, & or that could be broken if you engaged the four wheel at a high speed.
hope this helps !

 

He removed the vacuum actuator.

 

ok so I got around to checking it the plastic house the holds the cable is stripped on the inside so now I have to fined it at a junk yard which is going to suck