What would it take to keep the front axle from engaging when using 4-lo
on dry paved roads?

Pull the front driveshaft.

Unplug the connector to the actuator or pull the fuse.

What year? Which t-case? Electric shift or manual? In some cases, (2004 w/NP1 for example) you can make a fused jumper with a toggle switch to use in place of the 4wd fuse in the IP fuse block. This fuse runs the front axle actuator only, there is a seperate fuse for the encoder motor.

The truck is a `03 ccdw, electric shift, NP1. Whats an encoder motor?

encoder motor is what actually shifts the t-case, its bolted to the side. think of it as an electric lever that used to come through the floor

Thanks for the info. I didn`t realize it was that easy. If I would have asked a year ago I could have saved my Alli a lot of sweat.

Had an chance to try the 2wd lo-range deal this am. It worked great, but would not go back to 2wd hi until the key was off for 10 seconds. Any suggestion on how to get around this? I would really like to make this deal work.

I suspect that the shift actuator has feedback to the computer acknowledging that the shift happened. When the disable switch is on, the computer sees the request for axle engagement, but doesn't see confirmation of the shift since it didn't happen. You will probably have to send a phony signal to the computer, could possibly be done with the same switch that you put on to disable the actuator. I would have to look at the schematic to see how to do it.