Yeah...
don't.
The single advantage of the cable-operated (manual) jobs is that you can have low-range in 2WD for easy steering. Yay.
For every other operation, the non-thermal actuator is the way to go. The thermal kind get slow as the temp drops, and as they age, they get slower and slower until they just don't work at all any more. Seems like they tend to fail in cold weather, too.
My '97 has the non-thermal actuator. Works wonderfully.
My '88 has the thermal unit. Works adequately, but I've installed two of 'em in the ~140K miles I've put on the truck (total of 320K more-or-less) IF I had known about the non-thermal upgrade when the first thermal unit died, I'd have installed it then. I got a "lifetime warranty" thermal unit from NAPA, and used that warranty once already, so it doesn't make sense to swap now.
Thermal actuators:
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One electrical connector, screws right out of it's housing with a bigass adjustable wrench (or the correct-sized combination wrench.)
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They should have covered this thing in pinky-purple plastic. This is what the failed actuators DON'T do, and Vi_agra doesn't help. (Really? "V_iagra" is censored?)
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Pop the electrical connector, unscrew the actuator. Plug the connector back in. Turn the ignition on, put the transfer case in 4WD. If the thing doesn't extend in ~30 seconds, or doesn't extend at least an inch and the electrical wiring, fuses, etc. are OK...the actuator is done.
The non-thermal style requires an
updated wire harness kit, and that includes a spacer that goes into the actuator housing before you screw the actuator itself in. GM used to sell the kit, but of course they've discontinued it. Now it's available through Dorman and other aftermarket companies. You'll also need the non-thermal actuator itself.
www.amazon.com/dp/B001C6Q7Q2/?coliid=I3PBSUZLPVAG5&colid=2VLYZKC3HBBDO&psc=1&ref_=lv_ov_lig_dp_it
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