My 4x4 has lots of problems in the system so I removed the transfer case actuator motor and tried shifting into 4x4 manually with a wrench. The front axle never engaged. I was able to shift into my low range but I’m pretty sure even when in the 4 low position the front wheels didn’t engage. Do I just need to replace/ rebuild my transfer case?

97 blazer

 

You also have to engage the front axle by applying vacuum to the actuator underneath the battery. This is done through a vacuum switch located on the transfer case in the case of 3-buttom 4WD. Or in the case of 4-button "auto" 4WD it is done by a vacuum solenoid run by the TCCM on the firewall above the distributor. When the front axle is locked in (engine running) and LF tire on the ground, you should not be able to spin the RF wheel without turning the front driveshaft.

What you are doing is not practical, except as a diagnostic. But hopefully that answers your question.