well that didn't work out..... could not get the sleeve to turn, guess I'll just have to wait til spring and order new parts

 

OK... bringing back the dead, that pop/binding is back. it seems to be coming from the left side, I can feel it bind up once every tire revolution, then pop. not sure where to go from here.... things I've done since... all control arm bushings, all new tie rods, idler, pitman, lubed stops, complete alignment, changed CV shafts.... what the heck could it be? only happens at full right lock going forward. happens regardless of 2wd or 4wd

 

Just for grins & giggles, try disconnecting the vacuum line from the axle actuator under the battery, then drive it. If the noise goes away, the O rings inside the transfer case vacuum switch are leaking.

 

vacuum switch was replaced this spring with a new acdelco one...

 

Just trying to come up with possibilities based on your symptoms. Just cuz it's new, doesn't mean it's good

 

its def not engaging the axle, I've checked that already. I'm wondering if the bearing on the diff where the axle slides in could be going out? wish I had a gopro with a mag mount...would make seeing what's going on much easier...

 

Sounds like a good reason to buy a really cool "tool" to me.........

 

What about a binding caliper guide pin? Wouldn't take much lateral rotor runout to make it bind up.

 

nope, just did brakes, was binding before that...

 

its weird, only does it in forward and full right lock, not in reverse