MY FRONT AXLE WONT DISENGAGE,I HAVE HAD TO REMOVE THE FRONT DRIVE SHAFT TO SAVE SOME WEAR AND TEAR AS IT IS MY DAILY DRIVER.THE VACUME LINES TO THE AXLE FROM THE TRANSFER CASE ARE OK AND TIGHTLY CONNECTED.I HAD A JEEP DEALER TECH SAY THE TRANSFER CASE MUST BE REBUILT @ 1350.00 TO FIX THE PROBLEM.DOES THIS SOUND RIGHT?,WOULD I HAVE ANY OTHER OPTIONS?AS A SIDE NOTE THE 4WD INDICATOR LIGHT STAYS ON WHEN DRIVING BUT DOES GO OFF IF THE ACCELERATOR IS PRESSED DOWN SLIGHTLY AGGRESSIVLY,LIKE GOING ALONG THEN DROP THE PEDAL ANOTHER 3/4",NOT FLOORING IT,COULD THIS BE RELATED?THANKS FOR TAKING THE TIME TO READ ALL THIS,I HOPE SOMEONE CAN HELP.

is there another way to engage/disengage the axle?

Sounds like a vacuume leak don't it? I betcha finding and repairing the vac leak is all that ride needs.
AND I never heard of the repair your mechanic advised ...stay away from there in the future..
Find the leak and you will be 99% done.
Big JIm <img src="/forums/images/graemlins/pfft.gif" alt="" />

I would agree with BJ. When you press the pedal you will get a change in vacuum that controls the disconnect.
Posi-lock makes a manual conversion.
FYI, found this guy who made his own:
I think he sells them on e-bay

http://home.earthlink.net/~stevenschreiber/jeep/tech/cabledis.htm

Josh