When I was in undergrad, my roommate and I both left town for the summer for internships ...and he stopped paying the power bill.
We returned the day before classes started again to a similar fridge/freezer situation. Horrific is an understatement.
When I was in high school I had a 97 Yukon and was collecting parts for a 60/14 SAS.
Turns out that's not a feasible project on a high school budget, but I love seeing these OBS trucks get refreshed and built. ESPECIALLY in a road salt state.
For what it's worth I spent probably 3 years chasing a vibration exactly like you describe on my 01 4Runner. Three sets of tires, two sets of wheels, ECGS diff bushing, two sets of CV axles, adjustable rear upper control arms, and three driveshafts. It ended up being the rear driveshaft, and I...
I wouldn't try to operate it without that cover in place, as I don't think there's anything retaining the pinion gear other than that cover. It's been a little while since I've had it apart though, so I could be wrong. That said, if the actuator is moving at all, even to the wrong position, it...
The actuator also controls the CDL, so if you try to engage or disengage it you'll be moving that shift rod.
Have you checked your tcase position switches for function? I'm curious about your dash lights showing it's fully in position when it's actually not. That's an uncommon issue, so I'd...
The older style inserts were installed with the flange on top and the C-clip on the bottom. That instruction sheet looks like it's for the new style.
OP can you tell what happened? Is the groove in the insert damaged like the clip pulled out of it? Or did the clip maybe break and fall out?