[orangeisnon]

Hi All,
Here's today's premise: My 91 K2500 doesn't enter 4WD hi or lo because the wires going from the 4WD switch in the Transfer Case to the front axle actuator are sliced in half. When I shift to 4WD, the front driveshaft does engage but the front axles do not (expected behavior in this scenario).
What I want to know is: Would it be safe/effective to add a simple toggle switch in the cab of the truck that replaces the switch mounted to the TC, and use this to control the 4WD actuator? If so, would it also be safe to leave the TC in 4-Hi at all times, and simply use the toggle switch to control the 4WD? I understand that the front driveshaft will always be spinning and that there will be a loss of power/efficiency, but I drive ~4 miles a day on sidestreets and I'm not sure I would see a difference. If it would be a major difference/cause problems, I can also use them in combination (shift TC THEN flip 4WD switch).
Thanks.

 

[RayVoy]

Why not just fix the cut wires? Must be more your not telling us?

 

[orangeisnon]

Why not just fix the cut wires? Must be more your not telling us?

Yep, completely missed one part. The 4wd switch in the TC is busted. The connector on top is gone, and I can't get it out due to it being rounded off. I've already tried to fix it that way, but I can't find even a trace of the connector pins.

 

[RayVoy]

OK, you have me a little lost, you don't have a switch in the t-case, you have an engaged switch on the front actuator.

 

[orangeisnon]

OK, you have me a little lost, you don't have a switch in the t-case, you have an engaged switch on the front actuator.

The actuator is Dorman part 600-100. It's mounted in the front differential, and engages the front axles when triggered. The switch is part 600-506. That's mounted to the top of the transfer case. When I floor-shift into 4 hi or lo, the transfer case engages the front driveshaft and (is supposed to) close the switch, which provides power to the front actuator over the two (currently cut) wires.
What I want to know here is if I can cause any damage by separating the two systems (mechanical TC shift and electronic differential engage) by using a toggle switch for the actuator. I'm sorry if it's a dumb question, but I've never seen it brought up before.

 

[RayVoy]

OK, the confusion for me, is the electronic t-case use a switch that is in the axle actuator. When the actuator operates it signals the control module and the control module commands the t-case to complete the 4x4 function.
Apparently the manual is a bit different, no problem.
Now that I understand your system, I see no reason that your idea is worth a try, go for it!

 

[orangeisnon]

OK, the confusion for me, is the electronic t-case use a switch that is in the axle actuator. When the actuator operates it signals the control module and the control module commands the t-case to complete the 4x4 function.
Apparently the manual is a bit different, no problem.
Now that I understand your system, I see no reason that your idea is worth a try, go for it!

Thanks, I just wanted a second opinion before messing with the differential. I'll hook it up this weekend since there's an ice hurricane going on right now.

 

[RayVoy]

I'm getting the same thing in New Brunswick, where are you?

 

[orangeisnon]

Rhode Island, side roads of Exeter where they don't plow. Gonna be doing a whole lot of nothing today.
Actually, maybe I'll get some wires soldered up to a switch to prep.

 

[RayVoy]

That's a big storm, just looking at radar, its just leaving NC

 

[orangeisnon]

That's a big storm, just looking at radar, its just leaving NC

No kidding. Turns out I have to leave the house, so for the time being I got the 4wd working by crimping the cables together right before the TC. In the process killing my speedometer (again)...
I'll make it pretty when the snow is gone. For now, if it works it works.
Stay safe out there.