I just checked the actuator the vacuum is working properly the front axle is not engaging.

regarding the axle not engaging; have you tried pulling on the cable itself, and "see" (listen) if it engages? (truck off so you can hear it).

regarding the grinding issue; it sounds like you have the same problem i had on one of my other trucks. the syncro's are more than likely gone (worn out). i was fed up with that noise (sometime it wouldn't even engage), and i just got into the habbit of shutting off the truck when moving it between HI & LO range. even my wife didn't complain about having to do that (she shook her head alot while doin' it, but never complained about it.........much :icon_couchhide:)

your right about the cable my actuator was not grabbing it so i just had to pinch the clip down harder.

that really sucks to hear about possible syncro's being bad but it makes a lot of sense. thanks u for the info.