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I plugged off the solenoid and my AC now blows out the vents. Can I just leave it plugged off and just use the manual locks for 4x4 or do I need to find the leaks? Thanks for all the help and suggestions.
Yes, you can just plug the vacuum lines and use the manual lock on at the hubs. You just won't have ESOF at the hub.
Keep in mind that when you stated it was going into 4wd, the transfer case was engaging and the light on the dash would say 4x4 but the front hubs were likely not engaging because of the vacuum leak. You can double check to make sure the manual hub lock is working by locking in the hub, drive it a bit, put it in park, set the park brake and then reach behind the wheel and try to rotate the front axle joint manually. If it does not move, your manual lock is working as expected.
PS, I had one that was so gummed up with dirt from the vacuum leak in the hub that even though the manual lock would turn, the ratchet/spring system inside was not moving and the axle was not locking.
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