Lost engagement of 4x4 front axle after seal replacement on 2001 GMC 1500HD

[En4cer275]

I disassembled the front right axle on my truck and replace the outer seal for the axle.  After I reassembled the unit and drove the truck for a while, I had not needed to use the 4x4 until the following winter. I had tried to use the 4x4 and did not have engagement of the front end.  I realized after careful inspection of the engagement of the switch, Transfer case and the actuator on the front axle that I may have not put the front differential back together properly.  it is possible that I may not have set the engagement fork in the right place withing the housing/gearing?   That is the only thing I can think of that may not be right?  If that is the case, I suppose a disassembly is in store again?

[davester]

I would first check that the actuator itself is going in/out when shifted between 2wd and 4wd (as in, unscrew it and look at it while shifting).

 

If it is working, then yes, it would need to be split again.

[En4cer275]

Ugh, sounds like it engages, but will have to remove the actuator and look, hope that's all it is.  too cold now and no garage to 

do repairs in.  

 

Thanks for the reply