'98 Dodge Ram 2500 Dana 60 4x4 Troubleshooting

We isolated the problem to the axle vacuum shift motor (page 3-33 if you're using the full shop manual) and have decided to replace it in lieu of a pro-lock cable system. We may try that approach in the future. For now, isolating the problem to the Center Axle Disconnect (CAD) and the vacuum was best done while running the motor and having my assistant (wife) cycle the 4x4 selector with the right front wheel lifted.

[@andysierra6934]

When I tried too put my 2000 ram into 4x4 it makes a grinding and clunking sound I hope it is just from poor vacuum and it started right when winter is coming just my luck.

[@SSMan-jo6tf]

My question is,how much vacuum should be present?

[@canadaplace2be176]

That splin will bust up

[@canadaplace2be176]

Light switch okay

[@MrMarkCaudill]

Thanks, I watched your video and it helped me figure out what was wrong with my truck. KZbin is awesome.

[@kerrycoats7902]

Did it fill like wheels were making bad noises and popin when you lock 4wd that is the way my 2003 Dodge truck 2500 ! thanks Kerry

[@michaelcompton4049]

That was not a filler hose on there ,that is capped off . Its the vent hose for the whole axle . And that is the vent at the end of the hose not a cap ! The oil gets there from the diferential

[@Mr.DIY69]

Was the actuator (diaphram) the issue?

[@adriananoelle4699]

That “line” is a breather hose for the differential..

[@paulrieker5204]

COLD WEATHER GUM-UP Great to share info! My 1995 4x4 dodge wouldn't shift front collar over the spline. I replaced the vacuum system with a manual cable (in 2004). Fast forward to 3 degrees above zero, in 2020, the cable couldn't shift the collar over the spline, and I was desperate. I pulled the Axle Vacuum Shift Motor, where the fork shaft which slides the collar, realizing the shaft didn't move freely right/left. By reaming the Shift Motor vacuum, just to clear the "gum", the shifter worked freely. -Maybe the reason I felt I had to put a manual cable (in 2004), replacing the factory shift vacuum was lubricant goo. The goo which restricted movement of the collar, was easy to clear -with a drill bit - except laying in the snow at near zero degrees isn't your funnest new year activity... guessing and swearing for a fix - truck and trailer stuck, spinning it's wheels. Today its FIXED!

[@Atpowell93]

Great, informative, easily understandable and very well explained video. Thanks man!

[@rauldiazrool6880]

Q pedo porq se tubo q akavar qurroa ver q otra falla puede ser porq no entra 4x4 porq no actua

[@pamsmith5507]

Good video, well spoken, your good. I will attempt this, mine is not grabbing sure it's same issue, thanks for taking the time to put this up. You saved me a big bill from dealer.

[@richardcaudillo1108]

Will the Dana 60 bolt right in a 1500 Ram?

[@jaxturner7288]

Bolt right in? No. Could you easily adapt it to a use a 60? Sure.

[@1crazynordlander]

Are you sure that rubber hose with the cap isn't just a breather?

[@jeffreycallahan5173]

Yeah good looking out buddy thank man

[@joshuahannah5207]

Did it work having same problem in my 99 cummins put it in four wheel and nothing not even the light will come on so I'm gonna go check the same thing out good video man!!

[@257pathfinder]

Yes. When we replaced the axle vacuum shift motor, it solved our problem. Still no light, but that hasn't worked since we owned the truck. Now she engages quickly and fully.

[@patrickmuldoon3431]

Joshua Hannah did you ever figure out what caused your light nor to work? I replaced my actuator still no light but 4x4 is working I have replaced the light as well not sure what the hell is going on

[@TheDreadnaught7]

@@patrickmuldoon3431 its just the sensor to the actuator

[@ButchWhitehouse]

Thanks for posting. This is helping me diagnose my trucks problem. The transfers case on my 2001 3500 disengages but the front end remains in 4 wheel drive. Got some good info to help me find the problem. Thanks.

[@Elite_marine715]

That is a vent on that axle not a fill point

[@deasttn]

Do you fill at the differential fill hole?

[@mazeurbanski]

that hose is the vent line for the unit

[@deasttn]

Does it share oil with the differential? I lost just a few ounces of oil and want to replace the oil.

[@rafaelrivas455]

Jason ¿Sé puede eliminar las flechas y dejar solo la punta de eje en él Wheel hub apretado con su tuerca sin consecuencias?

[@pierceriegsecker1592]

Tuts the axle breather oil splashes in from the differential

[@justinmoorefield7226]

I'm having an issue with mine, I go to put it in 4x4 and it goes in and no light comes on and the 4x4 doesn't work. so I guess it's the vaccum?

[@erinmcneil2403]

mine is doing the same thing, sometimes it works, sometimes it doesn't, light comes on, goes off. was yours the vacuum disconnect?

[@Coryrose000]

hey cool video! i have a 98 ram 2500 v10 and it works fine in 4x4 but the light is always on, don't matter if its in 2wd or 4wd. any idea what could be causing that?

[@257pathfinder]

Cory, 9 times out of 10, an electrical issue is due to corrosion at the contacts. Try disconnecting the wiring harness and reconnecting it a few times...this should help to remove any corrosion at the contacts. Yours may more likely be a 1 in 10 though. In which case, you may have a stuck switch at the vacuum shift motor itself...which might require disassembly and actuation of the switch plunger (inside). I don't think that's worth the trouble (removing the shift motor, draining the fluid, replacing the gasket...etc.). I'd just disconnect the light switch harness and move on with life if it were mine! I grew up on a 4x4 that had no dash light. When it's engaged, you'll feel it through the steering wheel especially as the truck crawls or you're in a low traction environment (snow/mud). Good luck.

[@danjette8238]

It’s a faulty vacuum switch on top of the transfer case . When the transfer case is put into 4x4, the switch is activated to divert vacuum to one side of the diaphragm on the axle and thus locking the front axle. When put into two wheel drive, the switch diverts vacuum to the other vacuum port on the front axle diaphragm to disengage the axle collar. It’s important to remember that ‘this system is very simple, but very sensitive to engine vacuum or the lack of it, any leak in the system will cause the system to act up. Internal leaks in the lines, transfer case switch or diaphragm on the axle will cause the 4x4 to act up. Not much vacuum is needed, 9-13 hinge pounds will suffice, but it has to be constant. Also make sure both axles line up. The short axle on the carrier side has a dowel and the other one has a hole which the dowel goes in. There’s a plastic bushing in there. If the bushing is worn , which most of the time it is, the axles don’t line up, and no amount of vacuum will slide the collar over both axles. Hope this helps.

[@igetschoolied1244]

I added a posi lock and really nice. That is always a option.

[@larryavila5192]

Were can I get a posi lock for the truck...

[@dodgeoverland4x418]

does posi lock remove the use/need of this acuator? In other words, the acuator stays in its original location (to prevent fluid loss) but is no loger necessary?

[@danielordway4000]

That vacuum cable (red and black vacuume tubes) hanging in the video is something I need to replace on my 1998 Ram 2500. Someone cut them. I'd order it on line but I don't know what is called to find it on any of the web sites. Be good if you could post it here.

[@cubpak89]

Ive got the light that comes on now after replacing the actuator but no four wheel drive

[@tommcgrew2880]

Where can I find vacuum line harness

[@adams-we3ow]

When refilling fluid do u add it into the differential?

[@deasttn]

That's what I want to know, too. I'm Pretty sure it shares oil with the front differential.

[@Sp0rt4320]

Hey man awesome video! I got a a 99 ram v10 and the 4wd light won't come on. Whole truck shakes like a motha if I get on it and it seems to becoming from the rear like it's not making the full shift to 4wd. How did the new vacuum work

[@257pathfinder]

Our 4wd light hasn't worked in years…I did some superficial troubleshooting of that connection at the axle (actuate the fork slide manually and check for continuity between terminals with a DMM). The shaking for you may be a u-joint issue? Does it seem to shake more under power (i.e., "get on it") while also turning one way or the other? I suspect the '98 and '99 4wd systems are quite similar in that they are either engaged (spline collar slides toward the center of the axle connecting both sections and sending power to the right front wheel) or not. IF the vacuum is leaking (as ours was) this transition may take a while especially on a cold day. I noticed our's made this transition most slowly while high in the rockies (9500') on a 25F morning in the snow…axle fluid is slow to warm! The vacuum replacement seems to be working perfectly (still no light). The new vacuum was noticeably better than the old when tested (simply blew air into one side). Good luck.

[@pmitowski98]

Great video, thanks for posting it, solved my problem

[@Opelearthquake]

Do you have a followup video? I have a dana 44 and having similar issues. My light does come on, but no 4x4. Makes it fun on ice!! Great video!

[@257pathfinder]

Sorry, John. No. But I'd be happy to discuss finishing details with you: pathfinder7573 @ gmail .com

[@jacobward5908]

there is two vacuum lines do they both push air to move over into 4x4 and how does it retract back when you put it back in 2 wheel drive? is there a spring in the acuator itself?

[@maxsands3861]

They don't push air they pull, one pulls to engage the other pulls to disengage.

[@igetschoolied1244]

I will look at if can where i bought it.

[@mrcabojr]

great video, that was a lot of help, but I seemed to have a vacuum, and the actuator was bad so I replaced it, still no 4X4 any idea?

[@BassickS77]

did you have a grinding popping noise when.you lost your 4x4. I was plowing yesterday and I noticed slipping out of 4x4 and a popping or clashing sound no I got no drive from front axle in 4x4. light still comes on

[@raycharette5524]

Same here.. did you figure it out?

[@mtjohndeere]

my 4H is not engaging all the time but I can hear it spinning up in 4L. I crawled under and the actuator moves about 1/8th turn either direction. I think that's the problem but I cannot find any information as to how tight it needs to be. any idea?

[@04282]

quick question on the vacuum.. does it have to be in 4 wheel drive to check for vacuum?? and does the truck need to be running as well??

[@257pathfinder]

Paul, yes, if I remember correctly the truck had to be running to test vacuum (the pump is mechanically driven and combined with the power steering pump...it runs parallel to the block on the driver's side of the engine). I had my wife cycle through the 4x4 combinations with the truck running and the right front jacked up. WE MADE SURE THE TRUCK WAS OTHERWISE OUT OF GEAR SO AS NOT TO RISK A LURCH FORWARD IF HER FOOT SLIPPED OFF THE CLUTCH!! It's not the safest driveway troubleshoot, so be careful and think through the consequences carefully. As she cycled slowly (you might be able to activate the manual linkage through the floor from underneath without help if you had a pair of vice-grips or something else to move the lever. You have to be able to actuate the valve at the transfer case/transmission and then I felt for pressure through the red and black lines depending on the lever position. It was last year, so my memory of the process is a bit foggy and there may be a better way. Hope that answers your questions.

[@jorgegonzalez3103]

Can somebody give me some insight on the seal that sits in that shaft there, mine has needed replacing but it seems the area around where the seal needs to sit has corrosion type build up which fights every new seal trying to get pulled into there

[@marcusroach3645]

Nope what about if you are NOT getting Vaccume to the shifter

[@257pathfinder]

keep going upstream…to the transmission and then further as it may be the vacuum pump itself then. I've got a rebuild video on this channel and Gould (referenced in that video) also does a great hour long vacuum rebuild video. It's a bit involved but not terribly expensive if that's what's going on for you. Check at the transmission first though pathfinder7573 @ gmail.com

[@scatoutdebutter]

Did replacing the actuator fix the problem?

[@rebelwolves]

quick question.. do you have any limited slip while in 4wd? I have a 98 ram 2500 (gas burner. so dana 60 both front and rear) when I engage 4wd It doesn't want like to turn corners. Acts like the diff is locked together.

[@pierceriegsecker1592]

rebelwolves it's gear clash ur not supposed to turn tight in 4x4 in dry pavement

[@pierceriegsecker1592]

Because ur front wheel and rear wheel r travelling at 2 different soeeds

[@emiliosotelo2186]

What’s happens if I just weld it?

[@malcriado06]

Great video! Thanks for the info.

[@holycarmods66]

does it really make a difference with changing to that

[@257pathfinder]

Oh yeah. The shift motor was most certainly failing...it was leaking air when tested (I just blew through one of the lines) and the new part had us back in business. Each person's situation is unique though. If you'd like more help troubleshooting your particular issue, I'd be happy to assist.

[@brittfarms2018]

I have a 2000 dodge 1500, and four wheel drive don't work, I have had the front actuator replaced an still does not work.. soo I guessing itll be the switch on top of the transfer case that has the 4 lines sticking out of it... does anyone have any ideas that might help me out???

[@dunnoyolo2238]

My actuator is leaking oil around gasket were can you get the gasket at ?

[@deasttn]

Send me your address and $2. I just bought 1 gasket and they sent me a while box of 10. I have extra :-)

[@lulerlewis1606]

What causes it not to move in drive

[@jimskinger9613]

If you put vacuum on the vacuum actuator wouldn't it tell you if it was good or bad

[@chrisogle5353]

i have a 90 jeep Cherokee my 4x4 works when it wants to im done trying to fix it i put a new actuator in 2 times and still nothing i know the vacuum works fine im just going to get a posi lock kit it was only 150 about at amazon

[@kevinsimpkins8491]

sound like you need a new joint in your drive line man nice video

[@djfoxx9879]

thanks excellent video

[@canadaplace2be176]

U bead to hook them up. 4x4 all time bro!

[@brucerazor5202]

Thanks saves me alot

[@theodoreroosevelt78]

Thanks, that's the same shit my 3500 is doing.