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Wiring for updated New actuator for frt diff on 1996 C2500 4x4

Need wiring diagram for updated New actuator for frt diff on 1996 C2500 4x4. Have new harness, need to know where single brown wire splices in....Thanks...J

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Posted on Feb 08, 2009

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2002 Chevrolet S10 Pickup Car Stereo Radio Wiring Diagram
Car Radio Constant 12v+ Wire: Orange
Car Radio Switched 12v+ Wire: Dark Green
Car Radio Ground Wire: Black
Car Radio Illumination Wire: Gray
Car Stereo Dimmer Wire: Violet/White
Car Stereo Antenna Trigger: N/A
Car Stereo Amp Trigger Wire: N/A
Car Stereo Amplifier Location: N/A
Front Speakers Size: N/A
Front Speakers Location: N/A
Left Front Speaker Positive Wire (+): Tan
Left Front Speaker Negative Wire (-): Gray
Right Front Speaker Positive Wire (+): Light Green
Right Front Speaker Negative Wire (-): Dark Green
Rear Speakers Size: N/A
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Left Rear Speaker Positive Wire (+): Brown
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Posted on Apr 16, 2009

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SOURCE: front diff does not engage on my 95 chevy k1500

first make sure the new actuator is gettin' power. Do this by placing your hand on it while someone engages the 4-wheel drive. Then try cleaning your vacuum actuator valve and vaccuum lines leading up to it for possible holes.

Posted on Sep 13, 2009

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1996 Chevrolet Cavalier 2.2L SFI OHV 4cyl

This is a sample for an 1996 2.2L (VIN 4) engine schematic...

You can find more details and the Repair Guide about your model in (free register). Select the Year, Make, Model and Engine for access.

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Posted on Oct 14, 2009

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SOURCE: replaced actuator with updated plastic

Remove the actuator and with it out and still connected engage the 4wd and see if the actuator is extending.If it is then check to see if you have a problem with the front differential.If it does not then you have to check and make sure you hooked the wires up correctly.The brown wire has to connect to the brown wire on the switch on the top of the transfer case.Hope this helps.Good luck.

Posted on Dec 12, 2010

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I got a 97 Chevy 2500 put new front actuator in transfercase shift 2wd 4 hi 4 low but front doesn't lock in buttons just flash an there is power to it I'm kinda lost

did you put the actuator in the transfercase or the front diff if you did not but a new one in the front diff remove it and check it most likely its the one in the front diff should be easy to get to and can be removed without loosing any fluid

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Dec 09, 2010 | 1993 Chevrolet K2500

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Front differential actuator is not working and i can't find a broken wire

you most likely need a new actuator. sme thing happened to my old 1996 sierra that i used to have. gm has update actuator. get it, replace it and something tels me that it will work.

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you may have a bad frt diff seliniod, try unpluging seleniod and putting into 4wd, if fuse doesnt blow then you know its the seleniod.also take a look at the wiring at the transfer case for any chafed wires,some of these trucks use vaccum also to operate 4wd check the vacuum switches for shorts,ive enclosed a wiring diagram to help you ,hope this helps ,good luck.04178a0.gif

May 30, 2010 | 1993 GMC Sierra K1500

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The 4wd in my 1996 chevy silverado 1500 wont work and i would like to know how many volts should be travelling through the 4wd wires

On the full size, the front actuator is electric, not vacuum.

When in 4wd mode, a switch on top of the transfer case conducts 12 volts out to the actuator. Wire #50 (brown) is the 12v feed, and it conducts to the light blue wire (#900) to the actuator.
When shifted out of 4wd, the switch opens up and no voltage goes to the actuator.

Check voltage at the connector for the front actuator (at the front differential - it looks like a large bullet that threads into the front diff.) If it has 12 volts, the actuator is the problem. If it does not have 12 volts, check the transfer case switch and the power feed to the transfer case.

I'll assume it is the actuator, if the plug to the actuator is getting 12 volts when in 4wd.
The way this actuator works, is it is a sealed chamber that gets heated by voltage. When it heats, the pin in the end swells and pushes a shift fork in the front differential. The shift fork engages a spline on the passenger side of the differential, and boom! you have 4WD.

GM offered an upgrade to this actuator that is a motor instead of a heated device. However, it requires a small harness addition, a spacer, and a new actuator. It is about a $150 to $200 option.

If I were you, I would buy a new heated actuator. They are available at most auto parts stores, and are about $90. They are also on eBay for about $55 plus shipping. These are very easy to change - just thread out the old one, and thread in a new one.

Good luck. The actuator is usually the problem 90% of time but recheck all of the wire harness just to maker sure there is no short before replacing any parts.

Jan 07, 2010 | 1996 Chevrolet K1500

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very common for the vac, actuator on the frt. diff. to go bad..

Dec 13, 2009 | 1992 GMC Sierra

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acuator at transfer case or at frt diff if acuator is moving then axles to wheels should be turning and you may have a hub locking problem. if axles to wheels dont turn then the acuator tofront diff is no good not strong enough or bent shaft on acuator, some of these use a small shaft in front of actuator also make sure if this truck use this shaft check it for wear, lift truck remove actuator push inside arm in see if wheels spin turn frt shaft while holding arm in wheel should turn is they do, replace actuator, if they dont turn then diff problem,

Dec 06, 2009 | 1990 Chevrolet K2500

1 Answer

99 jeep

i still think that you need to look at the frt drive shaft assembly, i am not saying that you may still have a front diff problem but the problem that you are stating happens only when you have all four wheel locked in correct. pulling the frt diff cover is simple, you will be able to check the fluid condation and do visual inspection, but do not forget the transfer case and frt drive shaft trun the frt diff good luck

Dec 22, 2008 | 1999 Jeep Cherokee

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