I just flushed my hubs with aft4 4 times each. Filed them back up and turned wheel to 4 o clock to drain excess. re-plugged.

Now this is what i get. i did this whole process because this same issue.
the 4x4 is intermittent. i have to turn the wheeler off then back on sometimes to get the 4x4 to engage. every so often it will kick on if i turn it on and drive a little bit, but i don't like to do this. Sometimes i have to ride around and shut it off and back on in order for the 4x4 to kick on. I just don't want to get stuck down in the ravine as it's a steep climb up. i'm afraid one day it will not kick back in and i will have to leave it down below and walk up this steep (_,_) hill. I'm 40 and i'm starting to wear down if you know what i mean.

Thanks for any help or pointers anyone can kick my way. i have searched everywhere on the net and i find nothing.

 

If you haven't replaced the armature plates,I would do this along with checking the bearings,plus make sure the hub nuts are torqued back down to 12 foot pounds only! Could be the source of erratic operation. Plus check the small awd wiring under the front panel and the connectors,then trace back down to the struts for any shorts or cuts. OPT