How to: replacing the 4x4 front differential actuator

[laxman21]

Well, since my 4wd drive stopped working, I decided to fix it my self.

Since my truck is a 92 and failed emissions, I decided to start with the vacuum hoses. Now I still had vacuum at the actuator i decided to replace them anyways since they were cracking and deteriorating and you can't inspect every inch of them without pulling them. That fix can be seen here:
http://www.automotiveforums.com/vbul...d.php?t=498411

Since that didn't work, onto the actuator.

Removal:

On my truck, you have to remove the battery and the battery tray to expose the culprit. On earlier models it might be bolted to the fender above the wheel well so you don't have to remove the battery.



You need to unbolt the frame from the wheel well. The two bolts are in the wheel well, no need to remove the tire.


Next, you need to disconnect the cable from the actuator. Use a screw drive to pry the spring from the slot and pull cable out.



Next, you can remove the cable from the frame by pushing in on the retaining tabs.



I skipped this step and just unscrewed the actuator from the housing and switched them out. I thought it would be easier than switching the frames out, too.



The problem:



The replacement part, $10 at the U pull it yard. Got it out of a 2nd gen truck. To make sure it was good when I pulled it, I just compressed it and put my finger over to inlet to see if it would hold the vacuum.



After removing the frame:




Now just bolt everything back up in reverse, and you are done.





BTW, this did engage my front differential! The only problem now is that the vacuum stays on all the time.

Tomorrow I replace the Vacuum switch in the transfer case. Part# 89059420

[s10blazerman4x4]

Another informative post.i sent it to the Faq suggestions thread.

[billibong]

Another great post laxman, thanks and keep up the great posts!!

[laxman21]

Thanks guys.

There will be no how to on the vacuum switch. I couldn't get the new one to screw in. So I took it to my mechanic.

[billibong]

Sorry to hear about that laxman. Hope he doesn't get you for too much.

[loots-42]

Originally Posted by laxman21

Thanks guys.

There will be no how to on the vacuum switch. I couldn't get the new one to screw in. So I took it to my mechanic.

I had a problem getting mine started too. But I had one of those little mechanics mirrors on a telescoping pole. I was able to get a good look at it with that and then starting it was easy.

[rlith]

Good how-to. Something I would like to add though. While doing this replacement. Check all your vac lines for cracks and dryrot and replaace as needed. Also check the vac lines and your old vac actuator for the presence of transmission fluid. If fluid is found the transfer case switch needs to be replaced as well.

[s10blazerman4x4]

Originally Posted by rlith

Good how-to. Something I would like to add though. While doing this replacement. Check all your vac lines for cracks and dryrot and replaace as needed. Also check the vac lines and your old vac actuator for the presence of transmission fluid. If fluid is found the transfer case switch needs to be replaced as well.

He did.Lol he made an excellent how to on that.

[s10blazerman4x4]

Im gonna put a question i got in here since its basically the same.
Anyone know what year of the 2nd gen you can goto get this actuator thing?
I think i might pick one up and just replace it to see if this kicks the 4x4s ass since it goes in when it wants to. I got all new vac hoses and the switch so im gonna call it this actuator as the problem.

[laxman21]

Originally Posted by s10blazerman4x4

Im gonna put a question i got in here since its basically the same.
Anyone know what year of the 2nd gen you can goto get this actuator thing?
I think i might pick one up and just replace it to see if this kicks the 4x4s ass since it goes in when it wants to. I got all new vac hoses and the switch so im gonna call it this actuator as the problem.

Well, I pulled the replacement out of a 2nd gen for my first gen. I think it's the same up to the last year.

Yep. same from 83 to 04
http://www.1aauto.com/1A/4WDrive/Che...WA00002/127514



For a little more money, you can get a jeep.
http://www.1aauto.com/1A/4WDrive/Jee...WA00003/292587

[s10blazerman4x4]

Cool thats what i thought.Thanks

[OverBoardProject]

Just so you know this is what the cable operated alternative looks like



the inside pull cable to engage the 4wd



The cable it's self is verg good quality, but their supplied hardware is very cheap quality.

The advantage of this setup us you basicly have a low range 2wd, good for tight manuvers with a trailer on

[s10blazerman4x4]

I like that. I was seriously pondering slapping the posi lock system in it because of all the troubles with the system and that how it goes in automatically pretty much. But now that i know well i have known for awhile about this im gonna try to get one when i get to the jyd next.

[OverBoardProject]

It's a pretty basic system, if someone can find a source for the cable I'll rin to the hardware store and see if I can come up with a cheap alternative.

Other than the cable It's basicly only hardware store parts

[Rmbodie]

I was concidering a posi-lock cable system too . But if it is cheap materials it is not worth the $100 plus dollars for it . I have searched for a rigid cable to use instead but I can't find one long enough to reach .

Also check the vac lines and your old vac actuator for the presence of transmission fluid. If fluid is found the transfer case switch needs to be replaced

Thanks for this tip rhilth , I have this problem too . I know what my next job will be . Rob