rebuilt transfer case wont shift into 4wd

[JoshB]

I had to take my transfer case apart to swap out the input shaft for the 4l80e. when putting it back together I was having problems getting that stupid snap ring around the rear bearing. the bearing wouldn't come far enough aft. anyways, finally got it together I could spin it with my hands so I figured it was good. I put it in the truck and it wont shift into 4wd. In 2hi it drives like it should. if I put it into 4Lo it is definitely in Lo gear but only the rear tires. I can get out and spin the front drive shaft with it in 4hi or 4Lo. Everything else seems to work like it should, the 4x4 light even comes on, but I can spin the front drive shaft. This is a manual shift transfer case. and I have checked the linkage and its fine. Any suggestions before I take this thing apart again??

[straightaxle]

is the front axle engaging? There is still an electric actuater for the front end even on a manual shift t case. Maybe something is unplugged?

[JoshB]

I took the t-case back out and pulled it apart. As soon as I Split the case I saw it. Some how I thought that the 4x4 fork would do it's job laying on top of the, we will call it the "slider". The piece that slides over the synchronizer and connects the chain sprocket to the main shaft. I would give names to the parts but I do ' t remember what there called. If you have taken a t-case apart you could understand that this is no way you can miss it. I was up until 6am cleaning and rebuilding which just means I will NEVER do that again.