my problem is i always have vacuum at the acctuator goes into 4 wheel just dosen't release the half shaft. i have already replaced the vacuum switch on transfer. think it could be the encoder motor??don't want to buy if i don;t need it .

 

Are you sure your vacuum lines are installed correctly on the switch? Believe you have one inm one out and a vent line. If they are then something is holding the switch open. Really didn't understand your post too clearly about the half shaft.

 

I had the same problem with vacuum always present. Mine was a bad switch however. Ball was stuck. I woudl suggest that before you replace the encoder motor, you pull the switch off the transfer case to make sure it is functioning properly. After you pull the switch see if the vacuum goes away at the actuator. If so, there is probably an internal problem in the T-Case.

Also, when you are in 2-HI and the vehicle is in park, engine running. parking brake on and wheels chocked, reach under and see if you can turn the front prop shaft. The front axle needs to be disengaged, so you may need to pop off the vacuum line to make sure the front axle is not engaged when you do this.

This shoudl rule out whether the T-Case is truely operating correctly whether you have a problem with the new switch. As I have learned the hard way, new does not always mean good.

Just my thought on how to isolate the problem.