I think I have my 4WD problem tracked to the actuator on the front axle. Now that I have it removed I have a couple of questions.

1. Should I be able to slide the fork back and forth on the shaft by hand? Mine will not move.
2. I found several small pieces of something in the actuator housing. I am assuming these were on the ends of the forks to help prevent wear on the collar. Do they need to be replaced?
3. Is there any parts available for these actuators or do I have to go to dodge for the entire assembly (vacuum motor, housing, fork, switch, etc.).


Has anyone bought parts for these actuators and where?

Thanks for all your help!

 

You probably need to spin the pass side tire to get the shift collar to move.
I've bought the housing and vacuum motor separate from the dealer before so assume the other parts are also available separately. I was surprised the price wasn't all that bad, about $40 for both items.

 

I had my truck not going into 4wd after being in the water. Long story but the actuator fork should move by hand back and forth. You can test with a vacuum pump on either or the connectors on the diaphram. It should move the fork to the opposite side and also hold vacuum without leaking down. If it doesn't move try the other connection. I tapped on the fork with a mallet to loosen it up and sprayed WD 40 on the shaft to remove the corrosion. I also bought another vacuum actuator to replace from my Dodge dealer but it cost over $300 and so far is still sitting in a box as the old one is still working. I didn't have anything loose but as I remember there were some wear points on the ends of the shift fork so they may have come loose. Hope this helps

 

My local parts stores have no access to replacement parts for the 4WD actuator. Anyone out there have part numbers or sources other than going back to the ***********?

I wacked my fork a couple of times with rubber mallet and it came loose and started to work like it was supposed to. Guess the shaft was froze up inside the vacuum motor. I think when I was feeding this winter I must have hit something and bent the vacuum motor just slightly to put the shaft in a bind. Looks like I need a new vacuum motor because of the bent shaft and a shifter fork (at least the wear points for the tips).

I know I could go back with a posi-lock system but I want to stay with the stock vacuum system, it evidently worked just fine for the first 170K. If I fix the actuator it might just work for another 170K.

Thanks for all the help!

 

Think about the only non dealer part is the switch. Check a junkyard, the same actuator is used on the gassers, should be a ton of them.

 

An update on the CAD problem:

Dealer wanted $230 for vacuum motor alone and about $11 for a repair kit that contains the wear plates, cork housing gasket, and 4 bolts.

I started calling salvage yards and located one on the third call in Wichita, Ks. It is the entire housing with the motor and fork included for $45. Someone robbed the wear plates but for $11 kit from the dealer I'll live with it. He's shipping it today.

I think for $11 dollars and a little gear oil, I will be checking the wear plates in this CAD about once every year. I think this is a big reason why the slip collar get sloppy and allows the front end to come in and out and leads to more extensive damage to the CAD and possibly the axle splines.

Just my two cents, thanks for the help!