just buy a posi-lock best 150 i spent

 

I don't even remember what mine ran me, but, it was well worth it. I hate burying my truck in the beach sand...... There are other guys, who live in really crummy conditions, who've just opened up the CAD housing, slipped the collar over to the 4wd position, and spot-welded it in place... Just enough of a little tack-bump to keep the collar from disengaging, without seriously altering the heat-treatment on the axle piece. You could do that for "free", but, you'd pay for it in fuel, after a while.
----I saw it on the internet.....it has to be true...

 

they make a one piece axle that you can put in there. they are a little under $400. It does away with all of the vacuum lines and axle disconnect, and it shouldn't effect your mileage much. Even with the two piece axle the front driveshaft still turns when you drive, so your really not spinning anything new.

 

wasnt too sure if it had an electronic silinoid in t case or if it was manual ..... like shift on the fly t case ....

 

Save a ton of money and use the facotry CAD cover and actuator pin. Just replace the vacuum line with a manual choke cable kit from your local auto parts store. I've done it on several 1st gen trucks and never had a failure. It'll cost $10 and an hour of your time.

 

ahh .. the ol' cable trick ... herd manny good things about this lil mod ... cheep too ...

 

vacum systems suck on these trucks go with a pul cable type system save you a lot of problems! there is a little plug on the actuator housing if you unscrew the pug from the housing there is a little ball at the end of it, when 4x4 is enguaged the rod hits the ball in and sends a signal to the dash light.. its prob just gunked up and stuck in or maybe junk.. worth traking it apart and giving it a goo cleaning and work out then re install see what happens..

 

He said "vacuum systems suck" ........ hahahahahahahahaha!

 

LOL... yeah literally