WilberM3 wrote:your 2000 does not have a vacuum axle disconnect. that was pre-91. i'd guess your tcase is fine as well, though at that age its worth changing all the fluids as they likely havent been done more than once if ever.
the 4wd engagement is like strizzo said basically a synchronized manual transmission. its possible that one of the linkages between the 4wd handle and the transfer case's engagement lever is bent and therefore not long enough to fully engage the teeth. but like i said a fluid change could help a rough engagement too.
Would it be possible to pull the lever back too far? I can kindof feel two catch points in the area of 4wd high. The first one, and then i can pull back another half inch or so. I pulled it to the second point both times it happened, but i'm not sure my girlfriend would have had the strength to do that, so she probably just put it to the first one.
A fluid change is probably a good idea. The truck seems to have been very well maintained (owned by the owner of Ludwig Motorsports in Louisville, a Haltech dealer), but i know his wife was the one driving it, so who knows when it was last done.
I'll call my buddy at Tires Plus and see what they would charge for that. Trans fluid changes are one of those things that i REALLY hate doing.
Thanks!

