With this application you will still use the 4x4 buttons to engage the t-case but the cable will be used to engage the gears in the t-case that the faulty vacuum would normally do. When you pull the handle and lock it in the pulled position the t-case will be in 4x4 and when you push it in an lock it it will disengage. You may have to roll the truck forward or backward a bit to get it to engage.
Here is a breif overview of parts used and the process of how it was completed.
Heres the parts:
Compression Fitting (This acts as more of a guide than anything)
Washers (I only used 2)
I ordered this locking cable Heavy-Duty T-Handle Locking Cables - 10 Feet*-*Buyers*RO9D3.5X10
because its heavy duty and blends in well rather than the silver cables I have seen. It was $24 shipped to my door and I ordered it on Thursday and it arrived on Saturday.
Basically you remove the battery and battery tray to access the 4x4 vaccum actuator under it. From there you disconnect the actuator and remove the bracket from the truck.
Next you mark a hole in line with where the cable from the transfer case snaps into place and drill a hole for the compresion fitting to be attached into. Sorry I don't remember what size bit I used.
From there loose fit the fitting into place like this
Next you will mark a hole in the center of one of the corner braces and drill it to fit the handle in for mounting inside the cab and loose fit it like this (this is where I used the washers)
Next find a suitable mounting location for the bracket inside the cab and mount the brace for the cable handle and then run your cable thru a hole in the fire wall. Make sure it is a sturdy mount as you will be pulling on this pretty hard. I chose to just run it thru an exsisting hole but you can drill a new hole if you want just be sure to use some sort of file of grommet to lessen the sharp edges. Then run you cable thru the engine compartment thru the openings inside the fender down to where the actuator bracket is mounted.
From there remount the bracket and trim your cable to length. The best way to trim the cable is to pull the handle out couple feet and cut the outer cable then push the handle back in and trim the inner wire so there is extra sticking out.
Now mount everything as shown and clamp it tight. When clamping the wire onto the cable running to the t-case make sure to pull the handle out about 1/4in so that when you push the handle in to disengage the t-case there is enough travel to fully disengage (this may take a few adjustments).
Once you are finished with that don't forget to plug the vaccum line that was connected to the actuator with a screw or bolt that fits snugly so there is no vaccum leak.
Reinstall the battery tray and battery and go have fun.
If anyone has questions feel free to ask and I will help in any way that I can.