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From: Pete C. on 1 May 2007 20:58
"Steve W." wrote:
>
> Pete C. wrote:
> > My '97 Chev K3500 has the stupid "wax motor" actuator for the center
> > disconnect on the front axle. While it's generally worked adequately, it
> > looks like it may have finally died. It wasn't working this weekend when
> > I needed it so I had to do a bit of winching to get unstuck.
> >
> > I haven't had a chance to investigate to see if the problem is the
> > actuator, or perhaps the electrical to it, but since I'm having to deal
> > with it I'd like to fix it for good. I recall at some point a few years
> > after I got the truck that they switched to a better actuator that I
> > think is directly interchangeable. Can anyone confirm this and give me
> > the info on when this change took place?
> >
> > As an alternate, I know that at least one company offers a retrofit kit
> > that replaces the electric actuator with a cable operated all mechanical
> > arrangement, but that would be more work to install than if I can just
> > get a better electrical actuator.
> >
> > Thanks,
> >
> > Pete C.
>
> SLOW OR NO ENGAGEMENT OF FRT. AXLE WHEN 4WD IS SELECTED
> #76-43-01A - (09/18/1998)
> REVISION: 09/17/98 DIVS INVL 1 5 7
>
> THIS BULLETIN IS BEING REVISED TO ADD INFORMATION TO THE SERVICE
> PROCEDURE, ADD A NEW PART NUMBER, AND INCLUDE SCHEMATICS. PLEASE DISCARD
> CORPORATE BULLETIN NUMBER 76-43-01 (SECTION 4 - DRIVE AXLE).
> __________________________________________________ ____________________
>
> SUBJECT: SLOW OR NO ENGAGEMENT OF FRONT AXLE WHEN 4WD IS SELECTED
> (REPLACE FRONT AXLE ACTUATOR)
>
> MODELS: 1988-97 CHEVROLET AND GMC K MODELS EXCLUDING 1988-93 MODELS OVER
> 8500# GVW
>
> CONDITION:
>
> SOME OWNERS MAY COMMENT THAT THE COLDER THE OUTSIDE TEMPERATURE IS, THE
> LONGER IT TAKES FOR THE FRONT AXLE TO ENGAGE WHEN 4 WHEEL DRIVE IS
> SELECTED, OR THE FRONT AXLE DOES NOT ENGAGE.
>
> CAUSE:
>
> THE FRONT AXLE ENGAGEMENT ACTUATOR IS A THERMALLY ACTIVATED COMPONENT.
> BECAUSE OF THIS CHARACTERISTIC, THE TIME REQUIRED FOR THE ACTUATOR TO
> COMPLETE 4 WHEEL DRIVE ENGAGEMENT IS EXTENDED AS THE TEMPERATURE DROPS.
>
> CORRECTION:
>
> REPLACE THE FRONT AXLE ACTUATOR AND INCLUDE THE APPLICABLE WIRING
> HARNESS KIT. REFER TO THE PARTS INFORMATION IN ORDER TO DETERMINE WHICH
> WIRING HARNESS KIT IS NEEDED.
>
> 1996 MODEL TRUCKS WITH A BUILD DATE ON OR AFTER JANUARY 2, 1996 ARE
> CONSIDERED AS "96I". IF THE BUILD DATE OF THE TRUCK IS UNKNOWN, VERIFY
> THE 3 CHARACTER "AXLE CODE" ON THE FRONT AXLE LABEL IN ORDER TO
> DETERMINE WHICH WIRE HARNESS TO ORDER.
>
> THIS NEW ACTUATOR USES A MOTOR TO ENGAGE THE FRONT AXLE AND IS NOT
> AFFECTED BY TEMPERATURE. ON 1988-93 MODELS WITH A GVW RATING OVER 8500#,
> THE NEW ACTUATOR CANNOT BE INSTALLED AND THE THERMAL ACTUATOR WILL
> REMAIN THE SERVICE PART.
>
> SERVICE PROCEDURE
>
> 1. REMOVE THE FRONT DIFFERENTIAL CARRIER SHIELD, IF EQUIPPED.
>
> 2. IF NECESSARY, CLEAN THE AXLE HOUSING IN THE AREA AROUND THE EXISTING
> ACTUATOR. DISCONNECT THE ACTUATOR'S ELECTRICAL CONNECTION AT THE FRONT
> AXLE HOUSING.
>
> 3. REMOVE THE FRONT AXLE ACTUATOR BY UNTHREADING THE ACTUATOR FROM THE
> AXLE HOUSING.
>
> 4. INSTALL THE SPACER FROM THE WIRING KIT INTO THE AXLE TUBE WITH THE
> FLAT SIDE SEATED AGAINST THE SHIFT FORK.
>
> 5. INSTALL THE ACTUATOR MOTOR AND TIGHTEN UNTIL THE SHOULDER OF THE
> ACTUATOR SEATS AGAINST THE AXLE TUBE.
>
> IMPORTANT: IF BINDING OCCURS BEFORE THE ACTUATOR IS SEATED, REMOVE THE
> ACTUATOR AND RESEAT THE SPACER BY PUSHING ON THE SPACER WITH A
> SCREWDRIVER. THEN REINSTALL THE ACTUATOR.
>
> ON K3 MODELS WITH THE CAST IRON AXLE TUBE, THERE MAY BE A CASTING BURR
> WHICH MAY CONTACT THE EDGE OF THE ACTUATOR. THIS SHOULD NOT CREATE A
> CONCERN AND THE ACTUATOR SHOULD SEAT AGAINST THE AXLE TUBE. IF THIS
> CONTACT REMAINS A CONCERN, USE A DIE GRINDER IN ORDER TO REMOVE THE BURR.
>
> 6. CONNECT THE SERVICE HARNESS CONNECTOR TO THE ACTUATOR AND CONNECT THE
> 2-PIN CONNECTOR TO THE MATING CONNECTOR AT THE AXLE. FOR 1994 TO CURRENT
> MODELS, IN THE CASE OF A COMPLETE AXLE REPLACEMENT, REFER TO FIGURE 1.
>
> 7. ROUTE THE WIRING HARNESS ALONG THE EXISTING HARNESS ON THE RIGHT SIDE
> OF THE VEHICLE. ROUTE CKT 241 (BRN) OVER THE TOP AND TO THE LEFT OF THE
> TRANSMISSION. SECURE THE HARNESS USING PLASTIC TIES.
>
> 8. FOR 1995-97 INTERIM VEHICLES, LOCATE THE 4-WIRE CONNECTOR (C120) ON
> THE LEFT SIDE OF THE TRANSMISSION. SPLICE THE BRN WIRE OF THE ACTUATOR
> HARNESS INTO CAVITY D OF CKT 241 (BRN) ON THE ENGINE SIDE OF CONNECTOR
> C120. FOLLOW THE SPLICING PROCEDURE DESCRIBED IN SECTION 8A (ELECTRICAL
> DIAGNOSIS REPAIR PROCEDURES) OF THE APPLICABLE SERVICE MANUAL.
>
> IMPORTANT: THE NEW FAST AXLE ACTUATOR REQUIRES ONLY 1 SPLICE. - FOR 1993
> AND PRIOR VEHICLES, SPLICE INTO CKT 50 (BRN) BETWEEN CONNECTOR C152 AND
> GT101 (FIGURES 2,3,4). - FOR 1994 VEHICLES, SPLICE INTO CKT 50 (BRN)
> BETWEEN CONNECTOR C152 AND P101 (FIGURES 5,6). - FOR 1995-97 VEHICLES,
> SPLICE INTO CKT 241 (BRN) BETWEEN CONNECTORS C120 AND C100 (FIGURE 7).
>
> NOTICE: CONNECTIONS MUST BE WATER TIGHT IN ORDER TO PREVENT WATER FROM
> ENTERING THE CIRCUIT AND CAUSING DAMAGE TO THE COMPONENTS.
>
> 9. ON K3 MODELS, INSTALL THE DELAY RELAY, INCLUDED AS PART OF THE WIRING
> HARNESS KIT, AT THE ENGINE SIDE OF THE BULKHEAD, ADJACENT TO THE
> EXISTING RELAY. MOUNT THE NEW RELAY WITH SELF-DRILLING FASTENER, P/N
> 22510339. ROUTE AND SECURE THE RELAY WIRE HARNESS BEHIND THE RIGHT
> OXYGEN SENSOR HEAT SHIELD.
>
> 10. VERIFY SYSTEM OPERATION. WHEN SHIFTING THE TRANSFER CASE, YOU SHOULD
> HEAR THE ACTUATOR MOTOR OPERATE.
>
> IMPORTANT: THIS RELAY INCORPORATES A 5 SECOND DELAY FOR THE FRONT AXLE
> TO ENGAGE IN ORDER TO ALLOW THE TRANSFER CASE SYNCHRONIZER TO ENERGIZE.
>
> FOR 88-93 VEHICLES, IF THE AXLE HAS TO BE REPLACED, USE JUMPER HARNESS
> P/N 15313272. CKT 1695 (BLK/WHT) FITS INTO CAVITY A OF THE FAST
> ACTUATOR. THE CIRCUIT INCLUDES THE CABLE SEAL AND THE TERMINAL PIN. THIS
> CIRCUIT PLUGS INTO THE 5-PIN AXLE ACTUATOR CONNECTOR.
>
> 11. DO THE FOLLOWING STEPS IN ORDER TO INSTALL JUMPER HARNESS P/N 15313272:
>
> 1. LOCATE THE AXLE ACTUATOR 5-PIN CONNECTOR ON THE SERVICE ACTUATOR
> WIRING HARNESS AND REMOVE THE TPA. 2. REMOVE AND DISCARD THE CAVITY PLUG
> FROM CAVITY A. 3. INSTALL CKT 1695 LEAD (BLK/WHT) FROM THE JUMPER
> HARNESS THAT HAS THE CABLE SEAL AND TERMINAL INTO AXLE ACTUATOR
> CONNECTOR CAVITY A. 4. REINSTALL THE TPA ON THE 5-PIN CONNECTOR. 5.
> INSTALL THE SERVICE ACTUATOR HARNESS 5-PIN CONNECTOR INTO THE AXLE
> ACTUATOR. 6. CONNECT JUMPER HARNESS 2X2 CONNECTOR INTO THE EXISTING
> VEHICLE 4WD MATING CONNECTOR. 7. STRAP THE JUMPER HARNESS AND THE
> SERVICE HARNESS TO THE TAB ON THE AXLE TUBE.
>
> PARTS INFORMATION:
>
> P/N DESCRIPTION QTY --- ----------- ---
>
> 26060073 ACTUATOR ASM, FRT DRIVE AXLE 1 22510339 FASTENER 1 15313272
> HARNESS, JUMPER (Z SPLICE)(88-93 K1-3) 1
>
> AXLE CODE 12376316 KIT, ACTUATOR WIRING HARNESS (88-96I K1,2) ZLS, ZLT,
> ZLW ZLX, ZLY 12376317 KIT, ACTUATOR WIRING HARNESS (96I-97 K1,2) ZWA,
> ZWB, ZWD ZWF, ZWG 12376318 KIT, ACTUATOR WIRING HARNESS (94-96I K3) ZLX,
> ZLY, ZLZ 12376319 KIT, ACTUATOR WIRING HARNESS (96I-97 K3) ZWF, ZWG, ZWH
>
> PARTS, EXCEPT P/N 15313272, ARE CURRENTLY AVAILABLE FROM GMSPO. P/N
> 15313272 IS EXPECTED TO BE AVAILABLE 9-21-98.
>
> WARRANTY INFORMATION:
>
> SOME OWNERS WITH ACTUATORS THAT ARE OPERATING AS DESIGNED (5-30 SECONDS
> ENGAGEMENT TIME) MAY CHOOSE TO UPGRADE TO THE FAST ACTUATOR AT THEIR OWN
> EXPENSE. THE FAST ACTUATOR IS A NEW PRODUCT ENHANCEMENT AND SHOULD NOT
> BE USED TO REPLACE ACTUATORS THAT ARE OPERATING AS DESIGNED.
>
> FOR VEHICLES REPAIRED UNDER WARRANTY, USE:
>
> LABOR OPERATION DESCRIPTION LABOR TIME --------- ----------- ----------
>
> F0025 ACTUATOR, FRONT DIFFERENTIAL USE PUBLISHED LABOR LOCKING, REPLACE
> OPERATION TIME
>
> N6112 WIRING AND/OR CONNECTOR-REPAIR USE PUBLISHED LABOR OPERATION TIME
>
> IMPORTANT: LABOR OPERATION IS CODED TO BASE VEHICLE COVERAGE IN THE
> WARRANTY SYSTEM.
>
> FIGURES: 00 ATTACHMENTS: 07
>
> ATTACHMENT 1 - FOUR WHEEL DRIVE INDICATOR SCHEMATIC (94 TO CURRENT)
> ATTACHMENT 2 - FOUR WHEEL DRIVE INDICATOR SCHEMATIC (88-93 MODELS)
> ATTACHMENT 3 - FOUR WHEEL DRIVE INDICATOR SCHEMATIC (93 4L60E MODELS)
> ATTACHMENT 4 - FOUR WHEEL DRIVE INDICATOR SCHEMATIC (93 4L80E MODELS)
> ATTACHMENT 5 - FOUR WHEEL DRIVE INDICATOR SCHEMATIC (94 W/K3) ATTACHMENT
> 6 - FOUR WHEEL DRIVE INDICATOR SCHEMATIC (94 W/O K3) ATTACHMENT 7 - FOUR
> WHEEL DRIVE INDICATOR SCHEMATIC (95 TO CURRENT MODELS)
>
> Figure 1
>
> Figure 2
>
> Figure 3
>
> Figure 4
>
> Figure 5
>
> Figure 6
>
> Figure 7
>
> GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL
> TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE
> TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE
> INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE.
> PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY
> INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A
> CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR
> VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL
> MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR
> INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.
>
> COPYRIGHT 1998 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.
>
> --
> Steve W.
> Near Cooperstown, New York

That looks like it.

Thanks,

Pete C.
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Prev: A blast from the past.
Next: trooper won't hold idle