Hay there. i posted a a thread a while back about 4x4 not working, i figured out why. The shaft that slides the fork back and forth in the actuator was bent. any body know why or how this would happen.

 

Thats pretty impressive. Its a 241DLD right? All I can think of would be the shift fork binding on something, and trying to force it in, or a bearing being shot and allowing the main shaft to move and bend that shift rail. Still, that seems pretty hard to do, those shafts seem pretty stout. If you still have it apart, I would recommend, replacing the retainer rings while you are in there. I had mine snap on my mainshaft for the hi/low fork, and luckily it just wouldn't come out of low. But I've seen them get caught between the chain drive and the gears and cause the case to crack and or shatter the housing.
Sean

 

just to make sure its the actuator on the front axel.

 

My bad. I thought you were talking about the shift fork in the tcase, not on the CAD. So you wouldn't have the Tcase apart then. I haven't had to tear my CAD apart, so I don't know how stout those actuators are on the front axle.
Sean

 

i bent mine, smacked the vac actuator off of a rock and it ended up bending the shaft!