I have a '99 Limited. The other day I pushed the 4WD button on the transfer case lever which puts the vehicle into 4WD "open" mode. Everything worked fine until I pushed the button to put it back into 2WD. It would not go back into 2WD.

I went to the dealer and here's what happened. The service writer said the acutator is broken. It's a $900 part and requires 13 hours of labor because it requires removing the transfer case etc. Bottom line: $2,300 for the fix.

I asked the mechanic if he could get it back into 2WD for me. The mechanic said, no problem. He switched the two vacuum lines located in the engine compartment above the drivers side wheel well. OK, so now it's back in 2WD, but the dash light still flashes.

Question: if switching the two vacuum lines put the vehicle back into 2 WD, then is the transfer case actuator really the problem?

 

What he did by switching your vacuum lines was retract the ADD sleeve in your front diff. Your front driveshaft is likely still turning with your engine if the problem is in the transfer case. Get someone to look under the truck as you drive it slowly to see if your front driveshaft is turning. If you do get the transfer case fixed, don't forget to swap those vacuum lines again to get it to work correctly.

 

Anyone else?

 

So... did you check your driveshaft or not?

 

Yes, the front propeller shaft is turning. The problem is the actuator which is external to the transfer case, but it is pinned inside the transfer case, so it's big job to install a new acutator.

 

I am having a similar problem with my 2001. I am going to get a used case for cheaper than the actuator itself.

 

Haveing the same exact problem with my 99 Limited.....what did you end up doing? I have been driving around with flashing lights and a disengaged ADD sleeve.