I have been through the whole vac system and it moves the actuator as it should when I shift it to 4x4 (stick in the floor). It acts like it wants to lock in sometimes but wont stay in. If the engine is off I can slide the actuator with my hand with no resistance.

Is my shift fork my problem or should I resign myself and take it to my mechanic?

 

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Sure its not in the transfercase or Gem? Also a vacuum leak will cause a similar issue. It is possible to shift fork ears may broken.

 

Evrything moves as its suppose to. The polarity at the solenoids changes how it should and I replaced the vacuum lines just because I thought they were the issue. The arm on the actuator moves completely and as far as I can tell it doesnt move back.

would any good machine shop be able to swap out the plastic for the metal alternatives? I dont think I will want to do this a second time.