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I am not sure we are on the right path here. Lets do the following (I kibitz, you do the work. I'm not driving to Denver <img src="/forums/images/graemlins/smile.gif" alt="" />)

1. Jack up both rear wheels and put it in park and rotate one wheel. Report what the other wheel does.

2. repeat above in neutral and report results.

3. Jack up all 4 wheels and put it in neutral and tcase in 2wd and rotate a rear wheel, and report if one front wheel turns

4. shift to 4hi and repeat 3 and report back.

Ebrake must be off for all tests. I'd turn the key on for each, then repeat test with key off. Humor me...


Haha <img src="/forums/images/graemlins/smile.gif" alt="" /> ,
I just took it to a shop, looking at the job, not having proper tools and a helper, I gave up. Hopefully they wont charge me alot!
But I did do a couple of tests:

Backend jacked up:
- While in Parking: a bit of play, wheels turn oposite directin.
-While in Neutral: Wheels turn same direction.

Onething I am dead sure is that the problem is with the locker gear stuck and the spring (or whatever that retracts the actuator)is not doing it is job.
Another thing I mentioned about the 4H not being able to engage "on the fly"; is hopefully due to the the above problem. I should hear back from the shop by the end of the day today and will report back <img src="/forums/images/graemlins/cheers.gif" alt="" />