4WD Actuator Redneck Fix

[evilunclegrimace]

Yeah, cuz the PVC will eventually take a ****. That socket isn't going anywhere. Cool fact though, I bet that TSB is out there somewhere.

Actually no, it is because there was a shortage of the actuators for a time and customers were not willing to give up their trucks due to a parts shortage. The PVC pipe will last a very long time.

 

[TechNova]

related info

https://www.chevytalk.org/fusionbb/showtopic.php?tid/214851/

 

[kford47]

Hey everybody, new to the forum but have to say thanks for the post, went to use the plow truck and found out quickly it had no 4x4, performed this quick fix and got it up and running in 10 minutes.

 

[Schurkey]

That's a temporary fix because it's going to drop your fuel economy, increase wear and noise.

The front differential has known leakage problems, and not a huge grease reservoir. If you aren't paying attention to the lube level, and it gets low, having the axle permanently jammed into 4WD engagement will cause damage in short order.

The better fix is to either use a fully-functional thermal actuator (they can go bad slowly, where they take longer and longer to engage. A new one is faster) or to convert to the new motorized (not thermal) actuator.

The new-style actuator requires an updated wire harness. Used to be available from GM; now you gotta get it from Dorman. The wire harness allows you to install a GM/Dorman/Other brand of replacement motorized actuator. Those guys engage almost instantly.

The new-style actuator in a housing intended for a thermal actuator needs a spacer similar to your socket. It's included in the wire harness update kit. The new style actuator in a new-style housing doesn't need the spacer.

In general, I avoid Dorman products when I have a choice--they're almost all Chinese. But the harness may be made in USA; and at any rate, I don't know of any other source besides Dorman and the folks reboxing the Dorman item. Other actuators are available, though. Choose wisely.

Dorman 600-600 harness:
www.amazon.com/dp/B001C6Q7Q2/?coliid=I3PBSUZLPVAG5&colid=2VLYZKC3HBBDO&psc=1&ref_=lv_ov_lig_dp_it

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Dorman motorized actuator
www.amazon.com/dp/B000IZ490Y/?coliid=I2IO8OFN43UH7X&colid=2VLYZKC3HBBDO&psc=1&ref_=lv_ov_lig_dp_it

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[Hillwill27]

Omg thank you so much i did not have the money to repair my truck i did that 4x4 work

 

[Frank Enstein]

That's a temporary fix because it's going to drop your fuel economy, increase wear and noise.

The front differential has known leakage problems, and not a huge grease reservoir. If you aren't paying attention to the lube level, and it gets low, having the axle permanently jammed into 4WD engagement will cause damage in short order.

The better fix is to either use a fully-functional thermal actuator (they can go bad slowly, where they take longer and longer to engage. A new one is faster) or to convert to the new motorized (not thermal) actuator.

The new-style actuator requires an updated wire harness. Used to be available from GM; now you gotta get it from Dorman. The wire harness allows you to install a GM/Dorman/Other brand of replacement motorized actuator. Those guys engage almost instantly.

The new-style actuator in a housing intended for a thermal actuator needs a spacer similar to your socket. It's included in the wire harness update kit. The new style actuator in a new-style housing doesn't need the spacer.

In general, I avoid Dorman products when I have a choice--they're almost all Chinese. But the harness may be made in USA; and at any rate, I don't know of any other source besides Dorman and the folks reboxing the Dorman item. Other actuators are available, though. Choose wisely.

Dorman 600-600 harness:
www.amazon.com/dp/B001C6Q7Q2/?coliid=I3PBSUZLPVAG5&colid=2VLYZKC3HBBDO&psc=1&ref_=lv_ov_lig_dp_it

xc_hide_links_from_guests_guests_error_hide_media

Dorman motorized actuator
www.amazon.com/dp/B000IZ490Y/?coliid=I2IO8OFN43UH7X&colid=2VLYZKC3HBBDO&psc=1&ref_=lv_ov_lig_dp_it

xc_hide_links_from_guests_guests_error_hide_media

As of 2/5/22 the actuator is Korean made and the harness is Chinese.

 

[Schurkey]

Korean doesn't sound so bad...IF (big IF) the QA is done properly.

The Amazon web-page for the harness is still claiming "Country of Origin: USA" which I was already suspicious of.

 

[yevgenievich]

Actuator and connector can be picked from a junk yard. Then add some wire and follow dorman instructions.

 

[Schurkey]

...and fabricate a spacer, if the vehicle has the older housing.

I just recently found the dimensions of that spacer, on this site I think. But I don't remember which post. I don't remember if it was a "new" post, or one dug-up on a search.

And, according to the GM bulletin, the motorized actuator isn't a suitable modification for '88--93 K3500 vehicles (which MAYBE includes 8-lug K2500s; depending on if they have the bigger front differential guts.)

 

[yevgenievich]

For spacer, I just put old and new units beside each other and measured the difference. An old socket worked.