Actuator works with hand vacuum pump. vacuum is not changing when transfer shifter is move from engage to disengage. vacuum at axle actuator stays on disengage side of actuator.
SOURCE: Transfer case wont engage
shift into 4wd and move truck a couple of feet.
if light is still off, park truck block the wheels set the park brake jack right front wheel and try to hand spin the wheel if wheel doesn't turn 4x4 is functioning properly but there is a wiring problem use an ohmmeter to check the 4x4 switch wiring fuse and bulb
if wheel turns freely the front axle or transfer case is not engaged
attempt to hand spin the front driveshft if the driveshaft will spin the transfer case is not engaged check the transfer case shift linkage, problem is in linkage or transfer case internals
if the driveshaft will not spin the transfer case is engaged properly
with trnsmission in neutral or park start engine measure vacuum on the two vac lines at front axle shift motor . one line should have approx 20" vacuum. other line should have none
if no vacuum measured look for vac leak or bad vac switch
if both lines have vac look for a bad vac swithc or ruptured cad actuator diaphragm
if one line has 20" +- VAC
move transfer case lever to 2wd measure vac again lines should have swapped vac signals
if no vac switch bad or 4wd shift likage needs adjusting
if yes vac motor bad or stuck or shift fork stuck
remove vac shift motor from the axle attach vac lines to shift motor engage disengage 4wd
does shift motor plunger move at least 1/2 inch
no shift motor bad
yes check axle shift fork and vac motor for binging
SOURCE: Dodge 4x4 Doesn't Engage
It's probably the actuator located on the front axle on the passenger side. Also, check all your vacuum lines to make sure there's no broken or leaking lines.
SOURCE: My 2008 Dodge 1500 5.7
is the shaft from the transfer case to the front axle spinning? Check to see that your locker solenoid is still plugged in there's a plug on the drivers side rear of the engine about 10 inches from the starter that's the plug to the locker solenoid. If its plugged and your front drive shaft from the transfer case spins your locker solenoid is likely bad.
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