The zip tie did not break. I got under the truck again hoping to God that it was the ziptie just popped off. No such luck. The lever was still ziptied in place. Where did you purchase your kit?

 

Important information to know. With the zip tie still in place Jack up the front wheels and support. With the truck in 2wd spin one of the front wheels. The other one should spin the other way. If it does the front axle is still engaged. Shift to 4Hi and check to see if the front driveshaft turns. If it does the t-case is fubar'd.

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Nope the front driveshaft does not turn. transfer case is fine.

 

The reason I ask about the front axle staying engaged is that you may have rounded the teeth on the Drive Sprocket or the Lockup Collar in the t-case. Under high torque situations, like plowing, you hear a bang when they spread apart and the front wheels stop turning. When you slow down and lower stress they mesh again and the front driveshaft starts turning.

You may also have broken the coupler in the front axle. The only way to know for sure is to open it up and look. By far the easiest thing to do is to is to pull the front axle tube off and expose the parts. You do not need to remove the front differential cover to expose the mechanism. Removing the axle tube will allow you to change the parts in the repair kit. FWIW I removed the front cover to inspect for any other damage. Cheap insurance....

Here is hoping that it is nothing major.

Jean Marc Chartier

 

So i do not need to take out the entire front diff to change the fork out if that is the problem?

 

That would be the best news I have heard all year. Thats not saying much though its only january 3rd lol

 

You do not need to open the diff cover to replace the parts. I did mine by lowering the front axle, 3 bolts, unbolting the halfshafts, 6 bolts each, front drive shaft, 4 bolts, and then removing the axle tube 4 bolts. You will need a 12 point 12mm socket to remove the halfshaft and front driveshaft bolts. I use a ½ drive 12 point 12mm socket. Those bolts have lock-tight on them. A smaller drive socket could break.

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Thank you very much for all your help. I dont think I would have been able to fix this problem with out your help.