I have some weird 4x4 issues still. I have ESOF and I have 2 sets of hubs so i will explain what happens with both hubs. When the MANUAL warns are in the LOCK position and i hit the 4hi switch i get a horrible grinding until i come down to less than 5-10mph then it clunks in. When the warns are UNLOCKED and i hit the switch its totally quiet (which it should be grinding cause the hubs are front shaft aren't spinning). So things are totally backwards.
Now with my auto lockers, when they are in auto and i hit 4hi it grinds again until i slow down and then clunk everything syncs up. Now once that has happened i can dis engage the 4x and speed up then hit it again with no grinding. Its totally weird to me. I put a new shift motor on the t-case and even if i had a vacuum leak, that shouldn't have anything to do with the operation of the manual hubs. Any ideas guys? Something still screwed inside my t-case? Once its in 4x4 everything works just as it should.