4X4 wont engage
if the light comes on the dash the transfer case is engaging. The front differential actuator is probly broken, or the solinoids are bad they are located behind the battery. you can also check the vacuum lines that go from the solinoids to the actuator for leaks, cause if they leak it wont engage the front diff actuator. i would put money on the solinoids cause there known to get water on them and short out and crack if its really cold. But i would check the solinoids, the actuator and the vacuum lines. i hope this helps man. oh and the actuator is right next to the front diff it has a black cover thing on it so the oil doesnt get on it from takin the oil filter off.
I had the same issue with my 2004, and it turned out to be the transfer case shifter shaft. The mechanic said it was the first time he had ever seen it like that.
A telltale sign of a broken shaft is that the truck would be stuck in one setting. For example, my transfer case was stuck in 4LO but the rest of the system was not. You'll easily be able to tell if it's stuck in 4WD, because it won't drive right and the speedo will be way out of whack. An easy way to tell if your electrical components are working is to jack up both front wheels, crank the truck, and engage the 4WD. Spin each front wheel and see if the respective CV axle turns. If it doesn't, one of two things is wrong. Either some electronic component is shot, or that IWE is completely destroyed.
A telltale sign of a broken shaft is that the truck would be stuck in one setting. For example, my transfer case was stuck in 4LO but the rest of the system was not. You'll easily be able to tell if it's stuck in 4WD, because it won't drive right and the speedo will be way out of whack. An easy way to tell if your electrical components are working is to jack up both front wheels, crank the truck, and engage the 4WD. Spin each front wheel and see if the respective CV axle turns. If it doesn't, one of two things is wrong. Either some electronic component is shot, or that IWE is completely destroyed.


