We have a 2001 Silverado that began blowing fuses and the transfer case would go into neutral. Last night it popped 4 fuses and melted 2 paper clips. This does not matter if it is 2WD, 4WD Auto, 4WD Hi or Low. After the engine is off the steering wheel now does not lock either. We had to have it pushed into our driveway. Have any ideas?
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The problem could be a number of things from the dash switch to the encoder motor on the transfer case. Try turning the truck off for a few seconds, then turn it on - don't start it, try switching it to 4wd hi. you shoul'd hear the transfer case motor trying to switch gears., if you don't hear that then check the fuse under the hood for that system. If the fuse is good, then crawl under and see if you damaged the wires to the transfer case.
Cheak all wiring, one little **** in the wire will make a fuse blow. I had the same problem with my starter and i replaced the starter but it was still blowing the fuse, come to find out it wus a wire burnt into so cheak all wires carfully.
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.
THE TRANSFER CASE MOTOR IS NOT WORKING TO INGAGE 4 WHEEL DRIVE. CHECK WITH DOOR OPEN WHEN YOU PUSH 4 WHEEL SWITCH YOU SHOULD HEAR MOTOR INGAGE 4 WHEEL DRIVE. IF YOU HEAR MOTOR BUT STILL NO 4 WHEEL DRIVE THE GEAR ON MOTOR COULD BE DAMAGED. REPLACE TRANSFER CASE MOTOR.
I would check the wiring harnesses associated with the 4WD. It sounds to me like you have a harness rubbed through or pinched. If the fuse blows without engaging the 4WD, look before the switch (which may be on the transfer case if it is a manually shifted transfer case, which I believe those were) If it doesn't blow until you try to engage it, look after the switch. I'd be especially suspicious of the harnesses where they run around the transfer case and where they get to the axle shifting mechanism. It could be something else on the same circuit if there is anything else, which would also blow with it off, but I believe that circuit probably doesn't run anything else.
check transfer case electrical switch, sometime if it bad it will also blow the fuse. don'trecommend you put any higher fuse than recommend, If the fuse blow there is a short some where and by putting higher amp fuse you might short or burn something else beside the fuse. if that check out than check your transfer case motor, might lock up and not allowing the motor to turn instead it short the fuse. don't drive the car, just leave it in park, put correct fuse amp back in and unplug transfer case electric switch and turn the key on (dont start the car) and see if the fuse blow; if not plug it back in and see if it blow the fuse. if that is not the case, unplug transfer case wire, and do the same and see if it blow the fuse.
Its most likley the switch causing the fuse to blow, but you should start by disconnecting the front axle switch first and see if the fuse blows, if it doesnt blow, that switch is bad, if it still blows, plug it back in and disconnect the front axle acuator and see if it blows, if it doesnt blow, replace the acuator, if it still blows, then do the same with the relay, if it still blows, the short lies in the transfer case switch.