Actuator: Testing and Inspection

DIFFERENTIAL VACUUM ACTUATOR

Components:

INSPECTION





1. INSPECT DIFFERENTIAL VACUUM ACTUATOR
a. Disconnect the actuator connector.
b. Measure the resistance between terminals 2 and 6.
Standard resistance: 0.3 - 100 Ohms
c. Measure the resistance between terminal 2 or 6 and body ground.
Standard resistance: More than 0.5 MOhms
If the resistance value is not as specified, replace the actuator assembly

2. INSPECT DIFFERENTIAL VACUUM ACTUATOR OPERATION





a. Apply battery positive voltage between terminals 2 and 6, and check the actuator operation by sound, differential vacuum actuator status and continuity between terminals 3 and 4.
If the operation is not as specified, replace the actuator assembly

3. INSPECT LIMIT SWITCH CONTINUITY





a. Connect the actuator connector.
b. Push the 2WD/4HI switch and check that the 4WD indicator light comes on after it is blinking.
c. Check the differential vacuum actuator operation by sound.
d. Disconnect the actuator connector.





e. Check the continuity between each terminal, as shown in the chart.
f. Connect the actuator connector.





g. Push the 2WD/4HI switch and check that the 4WD indicator light goes off after it is blinking.
h. Check the differential vacuum actuator operation by sound.
i. Disconnect the actuator connector.





j. Check the continuity between each terminal, as shown in the chart.
k. Connect the actuator connector.

4. REMOVE DIFFERENTIAL VACUUM ACTUATOR
5. INSPECT CLUTCH HUB AND CLUTCH SLEEVE
a. Check the clutch hub and clutch sleeve for wear and damage.
If necessary, replace them.





b. Check that clutch sleeve slides smoothly on the clutch hub.





6. MEASURE SLEEVE FORK AND CLUTCH SLEEVE CLEARANCE
a. Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.
Maximum clearance: 0.35 mm (0.0138 inch)
If the clearance exceeds the maximum, replace the fork or sleeve.