Was having a problem with 4x4 so I took out the battery out to check the actuator and it seemed fine, checked the cable it moved fine put my jumper cables on and got the truck running and noticed that the actuator is always pulling the cable when the engine is running.
Now the 4x4 works but it is still pulling the cable all the time. What is causing this and what damage can be caused from this?
This is a 1995 3 button that is OBDII.
Thanks for any advice!!

 

The most likey cause for your condition would be a bad transfer case vacuum switch , which is located at the top of the transfer case, above the front output shaft. It will have 3 vacuum lines running to it and can be removed with a 7/8 wrench. The plunger will stick and cause vacuum to be applied to the accuator at all times.

 

^correct^

 

If you need to drive the vehicle before you get it fixed you could remove the battery and battery tray, disconnect and plug the vacuum line going to the actuator. This will keep the front axle from engaging, so you will not have 4wd, but will prevent damage. When this happened on mine I would get a noise similar to running over rumble strips occasionally and would have to come to a complete stop or switch in and out of 4wd to make the noise stop.

 

Cool thanks for the help, I just pinched off the vacuum line for now maybe next week I'll crawl under and fix it. Thanks again for everyones hellp!!!!