[Goodyguy]

Where do I start. Ok I have the 3 push button electronic switches.
I push the 4hi switch and it lights but no front wheel engagement. I push the 4lo switch it lights I hear the clunk but no front wheel engagement. If I drive a couple of blocks smoke starts poring from my exhaust. The smoke stops when I switch back to 2hi. I checked the vacuum actuator under the battery and the cable had come loose from the actuator. I lubed the cable and replaced the actuator ( it had a hole in the diaphram) I tried it again thinking I had fixed the problem. But after a block or so the smoke came pouring out again and when I tried to switch back to 2hi I could hear a noise coming from the front differential like it wasn't disengaging all the way. so I put it back into 4hi drove home disengaged the cable from the actuator and then could drive in 2hi without hearing any noise from the differential.

#1 What causes the smoke when driving in 4wd even without the 4wd engaging?
#2 Why doesn't the 4wd engage?
#3 Why the noise from the differential when going back to 2wd?
#4 There are no codes showing after doing the pin 13 ground trick.
#5 Do you think replacing the vacuum switch on the transfer case will help?
maybe thats why the actuator won't let the differential completely disengage when going back to 2wd?

Thanks,
Buddy Clark