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there's a vacum switch on my 86 that's on the top of the transfer case between it and the floor board. that switch operates a diaphragm located on the passenger fender well near the battery in the engine compartment. that diaphragm in turn is hooked to a cable that goes to the front axle, and engages. it. your problem could be the switch on the transfer case. that was the case on mine, and I decided that it was easier to route a manual vacum pump from the cab to that diaphragm to engage the front end than it would be to try to change out that switch. not reccomending this, just offering other possiblilites.

On my 94 S10 Blazer the vacuum diaphragm is under the battery tray. You have to remove the battery and the tray to access the diaphragm.

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Q: What is problem when front axle won't engage but transfer case does when shifted into 4wheel drive?
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