Thanks. Great resource. In 97 the axle doesn't have the flange, so I'm not sure that I'll be able to get the axle all the way out w/o removing the steering knuckle, but this gives me the info that I needed.

I have a suspicion that I have a very similar problem or possibly even worse that the dog teeth are rounded over so the sleeve will not slide across to join the gears. Probably as a result of a vacuum leak that I still need to track down, but I'm pretty sure that is in the switch on the T-Case. That little friend is buried up in no man lands. Looks like the front prop might have to come out to have a decent chance at access.

Off in search of hints for that piece. Thansk again.

 

You are right about that switch. You can see it you can barely reach up and grab the Rubber hoses on top. Getting a ratchet and socket on there and trying to have enough room for the Handle to swing. good luck

 

Was able to get the switch out w/o pulling the driveshaft. Very tight fit, but accessable.

Confirmed that switch was faulty. Ball pushed inand stuck. Routing Vacuum to actuator all the time.

Next step find out how much damage up in front axle area to see if I can actually get the front axle to engage. Actuator is good. Been pulling on the cable for who knows how long, but shift fork does not move.

 

Good thread, keep up on the updates please, I think I am going to be in your shoes before long. Thanks, mark

 

I'm sure you will want to open up and investigate. But With at least one front tire off the ground. Try to Push the cable toward the diff and slowly rotate the tire both directions. It might be enough to take the tension off the mated gears and let the spring/fork pop out of 4WD..