A few years ago, I replaced the worn out rubber grommets on my transfer case linkage with plastic grommets from a parts store. I have a 96 now that needs the grommets. Anyone have part numbers? I don't want to have to use the factory rubber grommets.

 

Found plastic grommets at NAPA and modified them to fit. Re-attached linkage, but 4WD STILL does not engage!

 

Can you feel the transfer case physically shifting?

It is probably the CAD system, which is on the front axle.

 

I can shift it into $WD manually, but never get front wheel traction. This didn't start until the bushing went out and I replaced it though.

 

It is for sure that the vacuum actuator then.

Either the vacuum is not present, the vacuum switch on the TC is bad, or the vacuum actuator is bad. There is a possibility the plastic on the CAD shift fork is gone as well.

Here are a couple of links to get you started,m one to troubleshoot, the other a quick way to test if it is the actuator.

http://www.dodgeram.org/tech/repair/..._engagment.htm

https://www.dieseltruckresource.com/...ir-t80742.html