Cracked front axle housing

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wws944

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BTW, I am familiar, conceptually, of what you are talking about regarding the original thermal vs electrical actuator. About 20 years ago, I used to follow a (long gone) Suburban forum where the upgrade was discussed.

My original thermal actuator seems to work ok. We tested it on the bench. After applying 12V, it takes a few seconds and does extend.

But it is interesting that comparing it physically to the integrated actuator/sensor, the latter is about 1/2" longer. Internally the various components are sized differently as part of the change. This is why using the two hole extension on the replacement front diff didn't work.
 
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