Removing 4WD actuator

Thousands of posts about 4WD problems; I can't seem to clear this up.

I'm trying to remove the rear 4wd actuator plastic case to clean it out, as has been posted hundred of times (eg here). However, the three 10 mm bolts that hold on the plastic case are so badly rusted I'm afraid they will break if I put too much more torque on them. (red boxes):



I've soaked them in rust dissolver and liquid wrench and torched as much as I can, but the amount of heat I can apply is limited because of the plastic actuator case.

My question is, can I remove the entire actuator apparatus from the transfer case? I can torch the hell out of the 3 bolts holding it on (blue circles), but I have seen posts indicating that removing the entire actuator cannot be done (or should not) without disassembling the transfer case.



Any thoughts on this? 2002 Xtra cab v6 automatic. thanks in advance

 

Let's say the bolts do break. You'd still be able to remove the actuator, then the remainder of the bolts that are left. Then you can get new bolts...they also might not break after all. Bolts that cannot be removed are not doing you any good.

 

Thanks. If I can get the whole actuator assembly off, I will be able to torch and hopefully remove the rusted bolts easier (the ones holding on the plastic cover). I could also drill them out in the event they do break.

 

Using an impact wrench will decrease the likelihood of snapping bolts.

 

Impact on the lowest setting?

 

To remove the entire actuator, I'm almost positive you'll have to split the case. There is a snap ring in there you'll need to release.

 

Before you start breaking bolts and whatnot. What makes you think there is an issue with the transfer case actuator?

If you put the truck on jack stands, does the front DS spin when you push the 4wd button / can you hear the xfer case actuator trying to engage?

There is another actuator on the front diff stub shaft (passenger side) which locks in the front end. I would be willing to bet that most of the time, it's the ADD actuator that's giving people grief.

 

Thanks. That was my understanding. It looks like on the second gens you can pop out a little gear and slide the whole actuator out.

 

Yeah, trying not to break rusted bolts. symptoms add up to the actuator not engaging, as if it is full of dirt and/or corroded. This was intended to be an “easy” check - pop off the plastic cover, see if mucked up…

haven’t done the jack stands test. The front actuator is next, although it too looks highly rusted and I anticipate similar removal issues.

 

Bold! Honestly, I don’t know if I have the courage to take my impact to bolts like this…

 

ok got it up on the stands and...low and behold, the 4WD driveshaft between the transfer case and front differential spins when I engage the 4wd button, but the front wheels don't spin.

so your inclination is correct and I agree it's most likely the front actuator. I sprayed it down with liquid wrench and will try to take it out tomorrow. it indeed looks like it's in an awkward location as many people have posted. thanks for the insight.

 

You might get lucky, and you have give it a whack and see what happens. More than one person has "fixed" things that way. Essentially the forks are stuck (due to not being engaged often enough). Clean the harness, give it a whack, and see where you're at.

 

Ok you were right and lucky i was (kind of). I gave it a few whacks and indeed the 4wd engaged. I then took it off the stands and took it for a spin, disengaged the 4wd and tried to engage it again, but in vain. I crawled under, gave it another whack or two, and it engaged.

This doesn't seem like a reliable longer-term "fix." Especially since the actuator isn't really accessible for continued beatings once the skid plate is back on.

Has anybody had experience with the whack-fix, specifically how long it lasted until the actuator kicks the bucket completely?

 

It's likely not the actuator kicking the bucket- it's that it's not lubed enough to allow the forks to do their thing. You need to remove the actuator and service it (lube it). Or replace it with a new or used unit. Getting it out is a bit tricky. There are a few threads about it floating around here. Be sure to include the terms ADD actuator so you don't get instructions for the t-case accutator.

You might be able to get away with things for a while if you can get it to engage and disengage a few times in a row (while up on the jackstands). This all comes down to the "you should engage 4wd once a month to keep things moving" in the 4wd components. It's any easy thing to forego during the summer months etc...