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long story short... 4x4 problems... i know i know ive already read the how to trouble shoot page. its a 1999 ford f150 with a 4.2 v6. my transfer is engaged manually. when i first got the truck the transfer case was stuck in 2 high. so i used a lot of penetrant and got it freed up. and then i realized the 4x4 didnt work. so i first ruled out the transfer case not engaging my opening the hood, taking note of how the front drive is position. then i would move the truck a few feet and take of not of the position it was in and it did rotate. then of coarse i checked the fuse and it was fine. then i went underneath and removed the cover and looked at the actuator. i moved the shift *** while my dad looked at it and he said it was moving. then we noticed the oil was a bit gray. so today we changed the gear oil. then i believe my dad put a vacuum pump on the diaphragm and it was able to hold 60 lbs. he even moved the actuator in 4x4 and still nothing. but that was before we changed the oil. so this is where im stuck...literally. anything im missing
teh vacuum cylinder on the axle has two hoses. one vacuum pulls the rod out and the other vacuum line pushes the rod in to engage. The vacuum is controlled by two solenoids on teh firewall. Start the truck and crawl under the axle and check both hoses, one will have vacuum. Switch to 4 x 4 and then check the hoses, the other should have vacuum. If not, check the hose routing, and check the output of the two hoses up at the solenoid end.
I had the same problem on my 03. Everything was moving and engaging as it should yet still had no 4X4. Turned out to be the shift fork in the front diff. New one installed and all is good again.
its almost like its stuck in between. when i used to put it in 4x4 low, it would clunk and clunk, then it eventually stopped. and recently i noticed that when you put it in 4x4 high and u give the truck a lot of gas it will clunk