4wd Not Engaging

[96chevyK2500]

I have a 96 k2500 and it won't pop into 4wd. I have already replaced the actuator on the differential and it still won't engage. I tested the actuator and it works. Any ideas?

Thanks!

[Chevylover]

I have a 96 k2500 and it won't pop into 4wd. I have already replaced the actuator on the differential and it still won't engage. I tested the actuator and it works. Any ideas?

Thanks!


What about the fuse ? Should be on the left side of the dashboard, when you opened the driversied door.

Floor shifter or electronic for 4WD ?

Cu,
Sven

[sixnickel]

With the actuator out, take a screwdriver and push it in where the actuator goes, and try to manually engage the front axle, make sure the transfer case is in 2wd. Reach and grab the front driveshaft and try to spin it. If it spins, your problem is in the differential, if it does not spin it could be in your transfer case. If you think its in the differential, pull the housing that the actuator sits in off and see if you can see anything busted up. All that is is a sliding gear on the axle shaft, it's pretty simple. If its not that, theres something broken inside the case. The whole differential is pretty easy to take out. Maybe its time to take a trip to the boneyard. Good Luck.

[96chevyK2500]

I checked all the fuses first and they're still good. It is a floor (manual) shift and the transfer case is brand new. The diff housing has plenty of oil in it and all the wires look good still. I'll try your suggestion. Thanks!

[Chevylover]

I checked all the fuses first and they're still good. It is a floor (manual) shift and the transfer case is brand new. The diff housing has plenty of oil in it and all the wires look good still. I'll try your suggestion. Thanks!


What about the adjustment of the linkage ? If the tranny is brand new, that sounds to me it is replaced, so it could be possible that the linkage is not adjusted as it sould be or it was right,but a nut or a bolt loosened ?

You also should check this switch : Four_Wheel_Drive_Actuator_Switch (http://www.ssdieselsupply.com/product_196_Four_Wheel_Drive_Actuator_Switch.html)


Cu,
Sven

[TedReminder]

My 94 is acting funny too. It engages 4X4 low just fine, no problem, but will not go into 4X4 high.
Any suggestions?
Ted

[Steeveo]

There must be some adjustment someplace. Mine engages perfect however the light on the push button keeps flashing about 95% of the time. Low is solid light though. Any clues?

[carlos]

i highly recommend getting the posi lok system i have got it on my burb and it works i dont have to go out and spend 300 bones to get a new one from gm. you will have s kmob under your dash and have to pull un it to engage the front diff but at least you know its engaging.

[mageep]

I have the same (or a similar) issue.. I have a 97 K3500 (non-dually) with a floor-mount lever. Just got the truck from Texas a few months ago, and never had checked the 4WD. Needed it today!

So today I pull the lever back... Nothing. No indicator light on the floor-mount console to show it went in... Called around and understand there's an electronc component on the transfer case (about $30), and a drive ON the front diff, which is closer to $150 - $200. I was wondering because the indicator doesn't change if I should start with the transfer case component first?

I am competent mechanically, but a little green on 4WD systems. Any advice on how to trouble shoot?

Thanks much!!!

[Chevylover]

I have the same (or a similar) issue.. I have a 97 K3500 (non-dually) with a floor-mount lever. Just got the truck from Texas a few months ago, and never had checked the 4WD. Needed it today!

So today I pull the lever back... Nothing. No indicator light on the floor-mount console to show it went in... Called around and understand there's an electronc component on the transfer case (about $30), and a drive ON the front diff, which is closer to $150 - $200. I was wondering because the indicator doesn't change if I should start with the transfer case component first?

I am competent mechanically, but a little green on 4WD systems. Any advice on how to trouble shoot?

Thanks much!!!


I would check the 4WD Fuse in the switch box first. Open the driverside door than you can see the box in the dash. If ok, you should check Four_Wheel_Drive_Actuator_Switch (http://www.ssdieselsupply.com/product_196_Four_Wheel_Drive_Actuator_Switch.html) . This switch is what supplies power to the Four Wheel Drive Actuator (TLA) p/n ssd-019. If this switch fails, you will have no four wheel drive. Than engage to 4WD and check if it works. If not, check the Actuator in the front diff. Wrench it out of the case and engage to 4WD. The Actuator should pop out, if not, buy a new one or replace with the POSI-LOCK System.

OEM Actuator 2 wire :
Four_Wheel_Drive_Actuator (http://www.ssdieselsupply.com/product_195_Four_Wheel_Drive_Actuator.html)

OEM Actuator 5 wire :
Four_Wheel_Drive_Upgrade_Actuator_Motor (http://www.ssdieselsupply.com/product_206_Four_Wheel_Drive_Upgrade_Actuator_Moto r.html)

Posi-Lock System :
PosiLok_4x4_Positive_Axle_Engagement_System (http://www.ssdieselsupply.com/product_201_PosiLok_4x4_Positive_Axle_Engagement_S ystem.html)


Cu,
Sven

[midniteplowboyy]

I have the opposite problem on my 94, it wont disengage, you can take the actuator out and it will, any ideas, is there a return spring in there or something that could be broke? Until it got muddy I drove around on an old actuator that I cut the end off of, but now I use the 4x4 prolly ten times a day and would like for it to work properly and disengage.

Thanks,

[Chevylover]

I have the opposite problem on my 94, it wont disengage, you can take the actuator out and it will, any ideas, is there a return spring in there or something that could be broke? Until it got muddy I drove around on an old actuator that I cut the end off of, but now I use the 4x4 prolly ten times a day and would like for it to work properly and disengage.

Thanks,



Replace the Thermal Linear Actuator with the Posi-Lock System !

PosiLok_4x4_Positive_Axle_Engagement_System (http://www.ssdieselsupply.com/product_201_PosiLok_4x4_Positive_Axle_Engagement_S ystem.html)

Manual but works if you need it and works not if you don't need it !


Cu,
Sven

[carlos]

just get the 4x4 posilok you will never have to spend the money ordering new acuator over and over agian. i have the posilok and i have 4x4 when i need it and i dont have to worry about a 300$ part burning out agian.

[mageep]

I would check the 4WD Fuse in the switch box first. Open the driverside door than you can see the box in the dash. If ok, you should check Four_Wheel_Drive_Actuator_Switch (http://www.ssdieselsupply.com/product_196_Four_Wheel_Drive_Actuator_Switch.html) . This switch is what supplies power to the Four Wheel Drive Actuator (TLA) p/n ssd-019. If this switch fails, you will have no four wheel drive. Than engage to 4WD and check if it works. If not, check the Actuator in the front diff. Wrench it out of the case and engage to 4WD. The Actuator should pop out, if not, buy a new one or replace with the POSI-LOCK System.

OEM Actuator 2 wire :
Four_Wheel_Drive_Actuator (http://www.ssdieselsupply.com/product_195_Four_Wheel_Drive_Actuator.html)

OEM Actuator 5 wire :
Four_Wheel_Drive_Upgrade_Actuator_Motor (http://www.ssdieselsupply.com/product_206_Four_Wheel_Drive_Upgrade_Actuator_Moto r.html)

Posi-Lock System :
PosiLok_4x4_Positive_Axle_Engagement_System (http://www.ssdieselsupply.com/product_201_PosiLok_4x4_Positive_Axle_Engagement_S ystem.html)


Cu,
Sven


Hey Sven, Thanks so much. That is pretty much the order I assumed was the best way to check, and your resource links were VERY helpful. Having not crawled under it yet (we were at 6 degrees F last night!), should I assume that, if the fuse is stable, and I need to replace actuator switch, is it located under the lever floor, an the top of the transfer case?

Thanks again!

[Chevylover]

Hey Sven, Thanks so much. That is pretty much the order I assumed was the best way to check, and your resource links were VERY helpful. Having not crawled under it yet (we were at 6 degrees F last night!), should I assume that, if the fuse is stable, and I need to replace actuator switch, is it located under the lever floor, an the top of the transfer case?

Thanks again!



If the fuse is okay, check if the switch supplies power to the Four Wheel Drive Actuator. Engage 4WD and check at the connector/prong at the Actuaor at the front diff if there is now 12V. If not, the switch is "dead" or something bigger INSIDE your transfercase.

Actually I can't say exactly where the switch is, but it should looks like :
http://www.ssdieselsupply.com/images/products/fullsize/196--20070106213306.jpg

Cu,
Sven

[rdang]

With the actuator out, take a screwdriver and push it in where the actuator goes, and try to manually engage the front axle, make sure the transfer case is in 2wd. Reach and grab the front driveshaft and try to spin it. If it spins, your problem is in the differential, if it does not spin it could be in your transfer case. If you think its in the differential, pull the housing that the actuator sits in off and see if you can see anything busted up. All that is is a sliding gear on the axle shaft, it's pretty simple. If its not that, theres something broken inside the case. The whole differential is pretty easy to take out. Maybe its time to take a trip to the boneyard. Good Luck.

You are correct.Mine hasen't worked for a couple of years.I'm going to remove the small housing,willing to bet it's a broken,bent shift fork.Looks like about a three hr job.