The acuator for front wheel drive wont work traced the problem down to the brown wire atached to acuator at other end is pulled out but do not know where it goes and also if i can can it be jumped from blue wire next to it i know the light will still flash for the 4wd switch but will that work
The brown wire you are talking about should have a whiteish colored plug. If you look very carefully at the junction box down below the dash, you should see a male terminal port to the right side of this junction box, it should have the abrieviation wht next to it. It is the switched power source, it comes from the 4x4 fuse in the upper fuse panel.
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That truck did not use a vacuum actuator, it used an electric motor motor. If your transfer case is engaging and you can see the front drive line spinning, then you either have a bad actuator, switch, or the wiring is bad. I would recommend unplugging your actuator and checking for power at the wire while someone puts the truck in four wheel drive. If there is power going to it, then replace your actuator. if not, follow your wiring back and check all components. They also sell an aftermarket cable actuator for those trucks which are much more reliable.
96 chevys have a ifs (independent front suspension) this give it more ground clearance but does not have lock out hubs, the cv axles go into the front differential an spin freely until you put it in 4wd, how this works is your transfercase spins the drive shaft that goes into the front differential an while you put it in 4wd it sends power to the actuator to lock the front differential. if your front end isnt pulling you either popped your 1 of your cv axles but if you did this you would know because it makes a very loud thunking noise while you're driving, my guess is you have a short thats not sending power to the actuator. check to see if the wiring harnesses are connected and check if the fuse that operates the 4wd in the cab of the truck is not blown. also actuators for these trucks are horrible they go out alot
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,
There is a swith on the xfer case. Do this...Key on engine off select 4wd. With a 12 volt test light go to the front axle and disconnect 4 way connector and check for power to front axle actuator (About 2 inch in diameter screws into axle on pass side) I believe wire color is brown. If you have power you have a bad acuator (unscrew from axle). If you do not have power you have a bad xfer case sw or blown fuse.
the front diff. is engeged by a thermal acuator in the front center section. check that the wiring on the pass. side of the front axle is of, if so the the acuator is probably faulty. Best to get an aftermarket posi-locking shifter if you need to replace the thermal unit.