well heres the story, the other night i was driving down a back road and figured what the heck ill throw it in 4low since i dont use it much, i noticed that the "low range" light didnt come on like it normally does. then i went to go from 4low to 2high and the "4x4" light stayed on then i was in 2high, so i got out and grabbed the front shaft and it was still engaged. so i got it home and hit the actuator on the front axle a few times and...nothing. it was late and -15 outside with winds going 20mph so i left it in 2high when i parked it and ill look at it in the morning. i got in it the following morning and when i started it i noticed right away that the "4x4" light wasnt on, so i tried 4high and it went in just fine, light came on, it didnt spin on snow so i knew it was in, then i tried 2high and the light went off and spun in snow so i knew everything was working... until i put it in 4low, the "low range" light didnt come on and but it engaged. i went to take it out of low into 2high and yet again the "4x4" light was on and the front shaft was engaged. so i went back to 4low and went from 4low to neutral a few times on the t-case and swung it into 2high and the light went off. then i tried 4high...worked great..2high..worked great. the issue only happens coming out of 4low. is there some sensor causing this? it seems really weird because it only happens coming out of 4low. we did get a bunch of snow this past week along with temps below "0" at times. 2001, 5.4, scab, manual shift t-case, AT

 

In order for your truck to go into 4L, you have to have it in Neutral, and your foot on the brake.
Rich

 

yes that is true when you have "shift on the fly" 4x4. since i have manual shift i gotta be at a slow roll to go into 4low. and a slow roll to come out. but what i was saying was coming out of 4L into 2H the front axle stays engaged when its supposed to disengage. the transfer case shifts just fine with no issues

 

mine is "tight". When setting still, i normally shift to 4 x 4, then take my foot off the gas and let it roll, or touch the throttle and move a foot or two, shift into neutral while rolling. Sometimes it takes a littel effort to get into or out of low. 2 x 4 to 4 x 4 in high works easier... especially if rolling.

 

same exact thing here. but my issue is a few days ago coming out of 4low (at a roll) i went to 2H and the 4x4 light was still on when i had the leaver in 2H. i got out and the front shaft was tight, so i went back to 4L rolled a bit and went from 4L to neutral back to 4L back to neutral then to 4L again, then i went to 2H and everything was back to normal, front shaft was free

 

Then your problem is with the front axle vacuum disconnect actuator or the associated solenoids. IIRC on a manual shift TC there is a switch on the TC to relate the mode you have selected to the 4x4 module .......IIRC. My source is down right now so I can't verify that. There are a lot of posts here regarding that though so look around.

One or the other solenoids (on firewall near battery) MUST have vacuum at ALL times. Sounds as if your 2wd solenoid "may" be dead.

 

BUT i can go into in and out of 2H and 4H with no issues, meaning that the front axle engages and disengages like normal. the ONLY time it wouldnt disengage was coming out of4L

 

OK, misunderstood it then.

 

i realize this is an old thread, but i need to know what the part number is or exactly how to identify the small part of harness that is attached to the solenoids in the pictures. any help would be great thanks!