97 chevy s10 blazer fluid in the 4wd actuator vac line

Ok I replaced the actuator and the cable leading down to the front axle. All was working well for about a month and now it's not. the actuator seems to be struggling to engage the front axle. I pulled off the vac line and noticed the actuator has a good amount of tranny fluid in it. Next thing I noticed the amount of effort to pull the cable using pliers is pretty difficult. I read as many threads as I could find about the transfercase switch letting fluid into the vac lines so I'm working on that. but what about that hard pull?

There's a fair amount of things that move in the axle housing when engaging the axle, so it does take a fair amount of effort. Parts 7 through 22 are all involved with engaging the axle:


http://i561.photobucket.com/albums/ss58/cwhook/4X4Frontdifferential-Copy.jpg

Might be worth while to take it apart and check to be sure.

As for the fluid in the lines and actuator.... The seals in the transfer case vacuum switch are leaking. Transmission fluid is sucked past the transmission rear seal, and the transfer case front seal. Fluid level in the transmission decreases, fluid level in the transfer case increases, the fluid migrates into the HVAC & 4WD vacuum system, (lines, actuators, mode switch, reservoir etc). Transmission fluid deteroirates rubber rather quickly and all of those parts contain rubber. Both the HVAC & the 4WD vacuum systems must be cleaned out. If you're lucky, the transmission and transfer case seals will seal as designed after the vacuum is removed.

There's a fair amount of things that move in the axle housing when engaging the axle, so it does take a fair amount of effort. Parts 7 through 22 are all involved with engaging the axle:


http://i561.photobucket.com/albums/ss58/cwhook/4X4Frontdifferential-Copy.jpg

Might be worth while to take it apart and check to be sure.

As for the fluid in the lines and actuator.... The seals in the transfer case vacuum switch are leaking. Transmission fluid is sucked past the transmission rear seal, and the transfer case front seal. Fluid level in the transmission decreases, fluid level in the transfer case increases, the fluid migrates into the HVAC & 4WD vacuum system, (lines, actuators, mode switch, reservoir etc). Transmission fluid deteroirates rubber rather quickly and all of those parts contain rubber. Both the HVAC & the 4WD vacuum systems must be cleaned out. If you're lucky, the transmission and transfer case seals will seal as designed after the vacuum is removed.

Ok I will let you all know what the outcome is.

Thanks!
In Christ
bradleypa