'89 chevy k1500 4WD suddenly not working

[tomeadie]

My 1989 Chevrolet half-ton K-series truck (5.7 engine, automatic tranny, 147,000 mi.) has four-wheel drive, which had always worked fine until about a month ago, when it suddenly just quit working. Now when I put into four-wheel drive, either high or low range, the front driveshaft spins, but the front axles do not engage, so neither front wheel turns. I assume this means the problem is somewhere in the front differential or axles or hubs, since the transfer case is evidently doing its job. So, how do I troubleshoot the problem? Somebody suggested to me that the thermal actuator is the likely culprit, but when I unscrewed it from the front differential housing and jumpered it to a source of 12 V DC, the plunger popped out about an inch or so just the way it's supposed to. I also checked the wiring of the circuit leading to the actuator, and it all appeared fine. The fuse for the 4WD circuit is okay, and I measured a solid 12.06 volts at the wiring harness that it plugs into with the ignition on and the shifter in 4H. So, I'm thinking that the thermal actuator thing is okay, although I'm not 100% sure. I'm worried that the problem may be an internal breakdown inside the differential, although I'm surprised that that would lead to a situation where neither front wheel works. I've known people with bad front differentials who got power to one front wheel in 4WD, but not the other. How exactly would I diagnose a problem with the differential? If there is a problem, what are my options? How hard is it to fix or rebuild it myself? What about buying a new, rebuilt, or junkyard differential? If the problem is not with the actuator, the wiring, or the internal gearing of the differential, what else might it be? Any advice would surely be appreciated.

[playtoy1]

im pretty sure it will be your actuator that is your culprit unless it is making noise from the front axle then your actuator isnt working properly

[tomeadie]

Once again, I suspected the actuator, so I took it off an bench tested it by jumpering it to a 12V DC source, and it worked. The plunger part of it extended about an inch or so, which was about as far as it felt like it could go. When power was removed, it retracted. I don't see what else it's supposed to do. Admittedly, I don't really understand how it works, but it appears to me that it is successfully "actuating" when current is applied to it, at least once it is removed from the vehicle. I also tested again to make sure that there was power at the wiring harness with the key in the "On" position and the selctor in "4H." Sure enough, 12.06 volts. So, I think the actuator thing is getting the proper electricla signal, and I think it's functional, so I'm supposing that the problem that's causing the four-wheel drive not to work is somewhere else. I don't hear any particular grinding noise from the differential when the four-wheel drive is engaged, so does that necessarily mean that the diffrential is okay?

[sakohntr]

These thermal actuators are very common for going bad. I highly doubt that anything is wrong inside the differential. There is also a kit you can buy to eliminate the actuator and install a manual cable to shift the front axle into 4 wheel. I think it is called
posi-lok. good luck

[dalejr8]

Another one of the late model gm fine engineering pieces of crap that acutator is bad it might still pop out a little but it is not far enough and does not have enough ass to engage itself.