Engine/Transmission (1998.5 - 2002) 4WD drops in and out

[AGibson]

I recently rebuilt my transfer case and think it is right. I replaced the bearings, seals, and forks. The chain and sprockets looked good. The oil pump appeared OK. At 300k and the bearings got loud. Now the front axle either locks up or engages with the TC in 2WD. My questions are how does the vacuum flow (sucks)? 1. Does it suck through the switch on the TC and then to the front axle. 2. Does the vacuum on the front axle keep it from engaging or does the vacuum help engage/lock up the front hubs? My truck 98. 5 4X4 and has shift on the fly (HD-241 TC)

Thanks guys!

Alan

 

[BWillard]

Maybe you reversed the 2 forks inside or maybe the "fingers"of one of the forks isn't seated in the groove of the gear. Just making a guess!

 

[AGibson]

I found my problem last night. Sometimes your the windshield and sometimes your the bug. Last night I was the windshield. The front axle locks and unlocks with the reversal of vacuum lines through the switch on the transfer case. My problem was a rubber elbow that seperated (located behind the axle and attached to the frame. ) It had the corrigated plastic tubeing covering it up. Once I removed it, I could see the problem. Just cleaned it and plugged it back in and put the corrigated plastic tubbing back. Works great!

Alan