I have a 95 Ram 1500 4x4. 318, 5spd manual trans, Dana 44 up front. I broke the front axles back in the spring. Swapped in some used axles out of a junkyard, now it won't go into 4wd. Vacuum is good on both lines going to the actuator, (like 20 inches I think?). With the right front wheel jacked up, I can feel the collar in the CAD catch both the intermediate and outer axle shaft when shifted into 4wd, but then it slips out and the light won't come on. There is a gap between the 2 shafts that I don't think is supposed to be there. Should the male end of the intermediate shaft always be engaged in the female end of the outer shaft or only when 4wd is engaged? Were there different length outer shafts used or is my inner shaft slipping back too far into the differential? If so what keeps the inner shaft in place? I don't remember removing any clips, blocks, etc. when I had the diff. out to replace the seals and axles. I can move it back and forth by hand at least an inch, I can mate it up to the outer axle, but it recesses when the 4wd actuator slides the collar over to lock the shafts.

My uncle told me after the fact that they have to be in 4wd when disassembled, but I've been unable to find anything to back this up.

Does anyone have any ideas what the problem might be? Is the inner shaft just out of place?

The truck now needs ball joints, tires, and alignment, so I want to make sure I get it all fixed when I have it apart this time.