I replaced my actuator today because it looked like it had exploded and it was full of case fluid and I pulled the t case vacuum switch it also was covered in fluid so it looks like fluid is being pushed through my vacuums for my 4x4 does any body know what I am a taking about and why there would be fluid in the vacuum.

 

You have a leaking front seal on the transfer case which is allowing transmission fluid into the transfer case. Sounds like a transfer case drop is in your future!

 

thank u!!!!! saved me a lot of time.

 

I just did mine. It was leaking like a sieve. Those front bolts on the T-case can be pretty stubborn. A friend of mine and me renoved and reinstalled it. We just horsed it out. I think it weighs about 80 lbs. We used a floor jack to support it but left it under the tranny and took the T-case out by manhandling it. Be aware of the hidden bolt that you have to get from under the rear (transmission) mount. You might also replace the gasket between the transmission and adapter. A new rear mount for my truck was only like $15.00 but it was wasted with the fluid that was constantly dripping on it. I bought it this way so I can blame the previous owner for the abuse. Really wasn't too bad of a job from a PITA standpoint. Oh, don't forget the vent line on top. Just some pointers frrom recent experience. Mine is a 94, but should be pretty much the same. If not, please ignore.

 

I got my 4x4 working to day it was way to cold today to try to drop the t case so I had tom at heavy t by my house take a look at it in his warm garage and It was just the vacuum switch did not have to drop t case and I replace the cooler lines today that was a big pain in the butt.

 

just so we know Brad, what year is your truck?

 

1988 jimmy gypsy 4.3 4x4

 

never mind 4x4 still does not work just confirmed tried to crawl over a pile of snow and ice 4x4 did not engage. new actuator and vacuum switch. when I put in 4x4 neutral it grands out of neutral. low on fluid maybe.

 

are you saying the t-case "pops" out of range (4HI or LO)?

 

no when in neutral when i manually take it out of neutral u can hear it grind going to 4hi or 4low and my front Axel does not engage at all.