Also check the wiring plugs that connect to the Tcase. I had them short together about a year ago and it caused me all kinds of problems.

If you donÆt have a vacuum leak then take the axel disconnect cover off and let it hang and have a look at its function. Turn the TOD on and off then turn the vehicle on and off. Make sure that the arm is moving back and forth properly. Also manually move the disconnect sleeve on the axel shafts back and forth. Make sure there is no binding, and the sleeve can move back on forth. You might have to turn (assuming that the rig is on jacks) the driver side tire to get the splines on the axel shaft to line up.

If the axel disconnect is working ok. Then have a look at the transfer case.


(edit) FYI post on TOD