vacuum issues
 

OK so here is all of what I have going on & nothing figured out so I'll start fresh.When I bought the truck I noticed this green vacuum hose was unhooked also so was the electrical connection to the exhaust brake. I do not believe there is an exhaust brake on this truck. I see nothing in the exhaust which is an aftermarket 6 inch, well I had air coming out of the front vents. put in a new transfer case and now No air out of anywhere but the defrost& the four wheel drive does not work.
I found this vacuum hose disconnected and if I run it to the Green Line... Which please if you know what this green line is for let me know anyways... I get four wheel drive but in a two wheel drive position meaning the linkage is in 2 high
& it only goes into 4 wheel drive in one of the positions though the 4 wheel drive light comes on in all positions but one. But still air only out of the defrost. I bought a posi lok to lock the 4 wheel drive in manually but I know vacuum leaks can cause excessive blow by so I want to fix the vacuum leak. I found the line with the disc is supposed to connect to the T fitting that is going to the exhaust brake. so I don't know if I should remove the exhaust brake and put it back to how it was originally because there still has to be something this was hooked too.And this braided line coming off the back of the terminal goes to a brown vacuum line it's actually kind of the squares line with black heat shrink around it what is this for? Sorry for the poor grammar I usually use speech to text but today its really bad I cannot use my right arm long story. any thoughts help ideas would be greatly appreciated.I do body work for a living and I was shocked yesterday that a fellow called me and wants me to come see his 2007 I believe 4 door long bed 4 wheel drive with the 6.7 he wants to give it to me for some work. But that doesn't mean I want to toss this truck aside.Ive Pub plans for a 2nd gen Cummins sense I learnt about them after I bought my 95 gas burner& I I have no plans to abandon this truck so please if you can help I would appreciate it plus I might change his mind or want to make some kind of crazy deal lol Thank you


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First thing I would get rid of all the extra garbage, yours appears to be either a 98 or a 99, there should be a single line from the Vac pump straight to the Tee in the second picture. Don't worry about the cap, they all have extra vacuum available from the factory.

Then I would get a vacuum gauge and start finding leaks. You might find it all functions correctly by just getting rid of the extra mess.

On my 2000, the vacuum system is pretty simple. A line comes out of the vacuum pump and goes to the cruise control. A line comes out of the cruise control and goes to a T shaped connector on the driver side firewall. A line comes out of the T and drops down to the transfer case. Another line comes out of the T and goes into the firewall for the HVAC controls. 2 lines come out of the transfer case and go to the CAD.

When I lost cruise and any HVAC setting except for defrost it was due to a fallen off cap on one of the extra openings on the T on the firewall.

Not sure if that will help you or not but that is the stock setup on a 2000.

Have a good look at the vacuum connector that plugs into the vacuum switch on top of the transfer case and make sure it's oriented correctly. There are four vacuum hoses in a square formation, and the switch has two index tabs sticking up that engage with two cutouts in the connector. It sounds like something is backwards there, allowing the front axle disconnect to go into 4wd position when the t/case is put into 2wd, and vice versa.