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Looking at the IWE sticky the worn gears are why I would investigate a stand alone switch to activate the IWE solenoid, or install a separate solenoid and check valve, to engage the hubs before putting it under load.
That's why I speced manual hubs and locked them in before I'm going to need 4x4.
But then I'm a control freak so ....
If when you had it apart and cleaned then lubed the system with 'heavy grease' you screwed yourself, I checked the temp in Va, you're in the teens ~ twentys. I'm guessing it doesn't usually get that cold.
Go do a little homework on the IWE system and then get back to us.
motor makes vacuum.... solenoids open and close the vacuum to the IEW.. Do you have vacuum on ONE side of the IWE ? When the solenoid is triggered, do you have vacuum on THE OTHER SIDE ?..... that side goes to the IWE hub... somewhere it is lost and need to check at the solenoids.
Rented a vacuum gun. Have 27 psi vac up to the actuator on the firewall. 0 at both left and right IWE in 4x2 & 4x4
Lung power is enough to determine if leak tight.
It sounds like you confirmed that vacuum is making it to the valve.
It sounds like you changed the valve.
The vacuum lines that run down to the IWE often get plugged.
The sticky thread says more than just change the valve.