91 front actuator motor

[Schmoky]

My 91 k2500 front end won't engage. I replaced the transfer case last summer and it worked fine until the middle of this winter. Now the front end does not engage. The transfer case manually shifts into low or high but the front end does not engage. I believe it is the acutator motor or front axle shift motor, not sure of the actual name but hope you know what I am talking about. I want to pull it out to check it, but not sure if it is as easy as it looks. I am concerned about the whole thing going SPROING and I will have pieces in my hand that I don't know where they go. Does anyone have an exploded view of what this is supposed to look like? any help or ideas would be appreciated. Thanks Schmoky

[ChevyTech]

It is common for the front axle actuator to fail.

I am concerned about the whole thing going SPROING and I will have pieces in my hand that I don't know where they go.

It is very easy to change.
It just unscrews and should stay in one piece.

If you take it out of the axle and start testing it, be careful because they get HOT. The actuator uses a heating element to expand the actuator.

[Schmoky]

chevy teck

thanks for the help. It just unscrewed and the new screwed in and now works like it is supposed to.

Thanks again

Schmoky

[ChevyTech]

You’re welcome. A thank you is always appreciated.

Glad to hear things worked out, and thanks for letting us know what fixed the problem.

[62 C60]

Chevy Tech, I read somewhere that you can put the actuator on a switch in the cab or something like that. you wouldnt happen to know of a link where I could find that would you?

[Schmoky]

62 C60

I replaced the transfer case in my 91 and the wiring for the actuator on the old t/c was a 2 prong and the new t/c was a 3 prong. Chevy wanted $50 for the one end of the plug so I just wired it to a toggle switch on the dash for $4. Now I engage the manual floor shifter to 4 wheel and throw the toggle switch and I have 4 wheel drive. The bonus is I have the option of 2 wheel low. By the way if I can wire it up anyone can. Electrical is my nemisis but was able to figure this one out. At least I think I figured it out, maybe my wiring is what make the actuator go on mine in the first place. Smokey

[ChevyTech]

Originally Posted by 62 C60

Chevy Tech, I read somewhere that you can put the actuator on a switch in the cab or something like that. you wouldnt happen to know of a link where I could find that would you?

I have not saved any links about his, and this is getting to be a time of year I will not spend much time on the internet.

My concern is if you install a switch toggle and you bypass the transfer case switch, you may forget to turn the switch off and the front axle will stay engaged.

[62 C60]

I did a search on google for "Chevy 4x4 Front Axle Disconnect" and this was the first link that came up. http://chevy.off-road.com/chevy/arti....jsp?id=200733
I think that product is pretty cool. I may just order one eventually, the only down fall is that there $230

[ed2552]

but they will never fail when you need them most

[62 C60]

Originally Posted by ed2552

but they will never fail when you need them most

yeah, but for ~$230 I could go to the local JY, get a ford D44 and some 6 lug outers (thats ~$150) with leafs. then go buy ~$75 worth of steel and make spring hangers and do a SAS.

(FYI ~ means about)

[ed2552]

true dat

[62 C60]

I think I may go that route sense my uncle works at a JY and I can get a discount.

[ed2552]

Yeah, the jy's around here aren't the greatest

[62 C60]

Neither are the ones around here. If your looking for an oddball part your SOL most of the time. They wont let you back in the yard to look yourself for fear of you getting hurt and suing them. But, my uncle knows I'm not a dumbass so he lets me look for stuff I need and if I find it I just go back to the shop get some tools and take it off and bring it to the counter. most places they just ask what you want and type it in on the computer to see if they have it and if they dont they wont go look and they wont let you look either. There is one really good one around here thats actually organized (by brand then by model) thats in Indy its ~50 miles away.