I went snowmobiling the other day and now have popping going on inside my front end when in 4wd and there is pressure on the drivetrain. I believe it is the CAD as I have already jacked up both sides, checked all 5 U joints and turned the driveshaft (Pinion feels tight and driveshaft turns with ease). All U joints look good and have no slop in them. The transfer case has very little slop as well. The only thing left is the CAD. I think the diaphragm inside the actuator has gone bad because I can suck on the side that pulls the CAD over onto the disconnected side and it holds the vacuum. If I suck on the other line, it does not hold vacuum. Is there anything else I'm missing?

Yeah... Just done the very same thing on my 1996 this last winter and fixed the issues.

the thread ibeen looking for. heres my issues. y2k ctd auto. the 4x4 light comes on but not as quick as it should sometimes. todayivacumed checked both sides of the accuator motor and it would not hold vacuum at all on either side. checked both lines coming in from the tc and both did hold vacuum i think i need the motor kit for a new diaphram ,sound right to you guys?

Yup! The diaphragm inside the actuator probably has a rip. I believe it was 110 bucks from Napa

Yup! The diaphragm inside the actuator probably has a rip. I believe it was 110 bucks from Napa

Thanks for the input guys I really appreciate it.