chevman said:
Ok so I done the test in the flow chart and it shows the problem is in the 4x4 disconnect now I know nothing about the disconnect is this an easy fix? Thanks for the help
It's not quite a "change your oil" job, and not a "removing cylinder head" job. I suppose it could be considered middle-road. There's a bunch of threads around here talking about the actuator. Some people have disassembled theirs, bought the part(s) they needed and successfully rebuilt the unit. Others end up placing in a brand new unit, which runs $300 or so. ATP and Dorman both have replacement actuators, sans actuator. Since it appears that your actuator is working okay (you didn't get a service 4x4 light at any time right? Just the symptoms you mentioned in the first post?) you can probably get away with getting a new disconnect unit without the actuator, and reuse your old one. Let me know if you need links.
The list of tools includes:
-Stuff to remove your tire. The tire iron in the standard tire change kit provided with the truck will do just fine, you could use an impact wrench or something if you've got the means, ends up saving time.
-18mm and I believe 13mm sockets to remove the brake assembly.
-35mm (stock) or 36mm (aftermarket) axle nut socket. You can use a 36 on the stock 35, it shouldn't hurt anything.
-Assorted other sockets and wrenches, can't remember the rest of the sizes.
-A pry bar just in case the actuator is stuck on good. In this case, removing the oil pan skid plate will allow much easier access.
-Torque wrench. Pretty well mandatory to make sure everything's as tight as it needs to be.
The video I've posted below may help a bit, but it doesn't appear to have a whole lot of action shots, which can be valuable sometimes. There's a ton of members who've had their disconnects off, sometimes more than once, who could give you a lot more first-hand experience than myself. I've also found an article on here, it's listed as how to replace the CV shaft, but includes removing the front axle disconnect.
GMTNation - How To: Replace Passenger CV Shaft with pictures
On the issue of fluids, since you're going to be wrenching anyways you should consider changing transfer case fluid. It's due every 50,000 miles and most people's experience on here is that the service interval is non-negotiable if you want it to stay working. You'll need two bottles of Autotrac II fluid, which can be gotten at the dealer or through Summit Auto Racing (Summit lists it at $7-8/bottle), and a 10mm hex key socket. A large allen wrench could be used, but a socket is better since you can use a torque wrench. Remove the fill plug before the drain plug to ensure that it comes off okay before you go draining the fluid out. Use a pump of some sort to get the new fluid in.
And most of us don't recommend using A4WD, instead skipping the option entirely. Stick to 2HI for regular scenarios, or 4HI or 4LO for all other scenarios. The way A4WD operates accelerates wear on internal components in the transfer case (specifically, the clutch pack) and a new transfer case (brand new, not junkyard) is $1500. In the end it's your vehicle and you're free to use it how you'd like, this is just our hearty recommendation from many people who've seen what it does to the system.
[video=youtube;p9kRAJRcxW0]http://www.youtube.com/watch?v=p9kRAJRcxW0[/video]