Check the magnet pole gap on the side that's slow to engage. Needs to be exactly flush to no more than .001" max
Did you replace the armature plates? They get worn too.

 

Not yet have a new one on order last part to do. Yes the gap is ok. Thanks

 

That’s probably your problem then. My awd has the Hilliard in the diff so different system but the armature was the problem with it engaging sporadically.

 

I HOPE IT IS THANKS

 

Got the armature plate today and did make a little difference in going into 4x4 but not all the time. I have had to hot wire the fan switch awhile ago and when i have the fan on the 4x4 goes in sometimes. Right when i turn off the switch the 4x4 goes in right away. Also tried the same thing with the hand warmers turn them off and same thing. Could the battery be going bad. The AWD is 12 volt power. Has any one heard of this. Might buy a battery later it is 5 years old. Thanks

 

Of course the battery has an effect - especially at low engine speed - the charging system has no output below about 2500 RPM - the ignition system does not require battery voltage and if the battery voltage falls sufficiently, the AWD can drop out - when a battery is low and an added draw like the fan, warmers or brake light cause an additional voltage drop.

A new battery might help, but the charging of the battery should not be neglected - it need to be maintained

 

Thanks I will try that and see if I can find a new battery. It's all I have left to do.

 

New battery and same old thing. One wheel has trouble yet. Where is the AWD sensor that turns 4x4 in when the tires break loose. I do not have it in the speedometer the only power is for the light. 1996 4x4.
Might be that sensor not working some times.

 

There is no sensor. AWD engagement it mechanical.

 

Thanks yes just found that out today.

 

Update on AWD replaced all components in the front hubs both sides. All new but still the same thing. Now one wheel sticks in forward also just like in reverse. For some reason the magnet stays energized
after 4x4 is not needed. Go forward in AWD and one wheel stays locked in and turns hard. Go in reverse one wheel is locked in some times. Did not push yellow override button. Magnets are not letting go sometimes. Have bypassed the shifter switch no difference. Why is there still power to the magnets when 4x4 is not needed. I'm lost. THANKS

 

What do you mean by “4x4 is not needed”? If the awd switch is engaged, there will always be power to both magnets which allows the armature to engage when there is slip. When you turn the awd switch off, the power should go away and the magnets should disengage, although it may take a few rotations for it to let go.

 

When I do not need to push the yellow button for reverse 4x4, one front wheel is still in 4x4 and makes it hard to steer. It should disengage when putting in reverse from forward AWD. Never had it do this before slow to let go of magnets. Thanks