I never changed the bearings i just swaped the whole set up from one in a junk yard.

I still think if you take it apart you will see the problem.

 

The cable pulls on the shift fork in the front axle to engage the collar onto both gears (the one connected to the differential and the one on the passenger side extension shaft). When you put it into 2HI, the spring inside (not the one you found - further inside) pushes the shift fork back to its neutral position disengaging the collar.

The pieces I am talking about can be seen in the images found in the link I posted above.

 

what i found i guess would be a retainer, keeper, not really a spring. i once againg tried pulling on the fork assy, im only getting 1/8 travel, not the .5 to .75 you have talked about. im going to drop the axle assy this weekend so i can see whats going on. i have called around junk yrds for parts, nothing.

 

Go to a pick a part or a upullit type yard they are always cheaper or you could just do a bravada/astro upgrade

 

Sounds like the teeth on the gears & collar have rounded off and is prohibiting the engagement. You can see the start of the teeth rounding off in the picture from the link I posted above.

As far as the Bravada/Astro upgrade, that will be certain to keep your front axle engaged all the time, however, it will not be as nice on fuel economy. If you just swapped the passenger side extension tube and axle shaft, you could cut down on your cost. I still think your diff is perfectly fine.

 

Tell you what i will send you the tube shaft collar every thing on the side you pay shipping i have two laying round shipping will probly be like 25 dollars no sence in throwing away if you need them

 

great. i sent you a private message with my ph number, thanks