I've gone through everything up to the point of the actuator working in my hand. Transfer case locking Front Drive shaft etc.
I'm down to internals in front Diff. My questions is there a "weak link" in the diff I can easily inspect/replace, or is it a R&R and overhaul? Maybe an axle that tends to have the splines wipe off easily? Any info is appreciated Thanks Tim.


1995? floor shift 4x4 Electric Actuator, lights on shift console light.

 

You won't have to R&R the axle. You will have to remove the passenger side extension tube which isn't too bad of a job depending on experience levels.

 

So generally the Rt Axle loses its splines? It looked pretty easy to get out. Thanks.

 

Is the fork a common problem?

 

I have seen the collar split as well as the splines on the outer shaft (the one closest to the passenger side wheel) round over chewing up the collar and the shaft. I haven't physically seen a broken fork, but I have seen pictures where others have experienced that failure. It just depends on which part is weaker in that assembly.

 

..start at the right wheel and start digging till I find sumthin broke... :/

 

Here's what it will look like once you get the passenger side extension tube off:

 

Looks Super Simple, thanks for the pic. I have lift space booked for Thursday night. Thanks for you help. I'll let you know how it shakes out. Tim