As it turns out, if you disconnect the vacuum from the front diff diaphragm, the differential will disengage. So let it be known that the 2nd generation montero does not have a fail proof system. Unless mine is just jacked up.
Now it makes a little more sense.... The way I see it is that I was losing negative pressure to the engagement slide therefore lessening the grip of the slide to the diff itself. I will open the differential this week to see the theoretical damage.
Now may be a good time to fab up a solid front axle for this thing.

. I'll compare the cost to the benefit and go from there.
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