I have a 1995 K1500 Z71 (that I dearly love) and finally got tired of the stock thermal actuator in the front differential.
Went to the wrecking yard and pulled a servo motor actuator out of a 2004 or 2005 K1500 and did some research. I decided to make my own wiring harness and am very pleased with the results.
Attached below are the schematics I got my information from.
I also found a helpful GM Service Bulletin (No: 76-43-01A) That clarified some.
I only used three conductors and three pins on my wiring harness.
Pin C (+): Brown Conductor - +12vdc Fused Actuator Servo Motor Power
Connect to Brown Conductor found on switch on Transfer Case above manual shift linkage)
Pin E (-): Black Conductor - Chassis GROUND
Pin D (+): Light Blue Conductor - Actuator Command Conductor
Connect to Light Blue conductor found on switch on Transfer Case above manual shift linkage)
When ignition key is on and transfer case is pulled INTO 4WD, the transfer case position switch CLOSES and SUPPLIES +12vdc onto the Light Blue Command Conductor and the actuator is told to EXTEND.
When ignition key is on and transfer case is pulled OUT OF 4WD, the transfer case position switch OPENS and REMOVES +12vdc from the Light Blue Command Conductor and the actuator is told to RETRACT.
I connected the wiring and did my tests to make sure the new GMT800 actuator would behave properly before I threaded it into the front diff.
I DID NOT USE PINS A & B
Pin A goes to the GMT800 4WD ENGAGED indicator light
Pin B goes to the GMT800 EXTEND/RETRACT GROUND CONNECTION.
A couple of details:
Actuator length differences:
I did a test with an older GMT400 thermal actuator and compared it's length while extended and retracted with the length of the GMT 800 servo actuator while extended and retracted. The GMT800 actuator I got from the wreck was shorter so I decided to make a small block of white UHMW around 1/2" long and inserted it into the axle so that the newer actuator would be sure to fully engage the splines. It sits in the hole loosely and I can reach in with a small screwdriver and pull it out if I want.
Wiring Harness
I did not want to ****** the stock wiring so I could go back to a thermal if I wasn't pleased with the results so I used a burned out old thermal actuator wiring harness plug and used it as my adaptor to connect to the stock wiring harness. I also bought some black plastic "conduit armour" to protect the new harness. Looks good and no carnage!
Results
It used to take a few seconds or even longer to lock in the front axle before my mods.
Today it is -34 degrees Celsius (which is -29 in Amrikaan Farenheit degrees) and it works beauty, eh! (Yes I'm from Candada). Instant lock!
Not sure who supplied some of the drawings I used but most grateful for the info on this site.
Hope this helps!