I know the vacume lines are good, actuator is good cable is good just the shaft and the outer gear wont lock in. They might just be frozen. Does anyone have a break down off the front diff before I tackle this thing this weekend?

 

Here's a shot of all of the components laid out after the passenger side extension tube has been removed:

 

So the only thing i have to remove is the extension tube to get to the collar? I was just reading about the upper ball joint in the way

 

Have you looked at it?? You need to remove the CV shaft to get the passenger side extension tube out. It depends on your year as to what needs to be done to get the CV shaft out of there.

 

i just did this one Saturday morning. i replaced the upper ball joint while i was in there. this is on a 98 4dr. 2 18mm bolts on the frame 5 15mm bolts on the transfer case. unhooking the upper ball joint gave me room to pull the cv shaft off the extension tube. unhook the cable at the actuator that will give you enuff room to unhook it at the shift fork collar its a spring lock deal. i found the gears in the extension tube had been drug over and keep it from locking in its held on the extension shaft with a snap ring. after i filed the teeth back down i test fit the collar ring just to be sure.

 

But if you have the bolt on flange style CV axle, it is much easier.