Join Date: Oct 1999
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Re: 91 Chevy will not go into 4 wheel drive
the way you test the actuator is to engage 4wd and actually watch the actuator extend (or not if it is busted). the actuator is in the front differential. take a crescent wrench, set it to mmmm, around 3/4" and unscrew the actuator. leave it plugged in so you can test it. don't fprget to have a rag handy. you'll get a little gear oil spill when you pull out the actuator from the diff.
i don't understand what you did with this "putting a rod in the transfer case and pushed a button that the actuator pushes". why would you be sticking rods in the tcase?
the 4wd indicator switch is located on the differential too. it is screwed in. if you take it out, it is just a little spring loaded buton that comes on when it is activated by the gear pressing on it inside the diff. i had this go bad on my truck. the button got a little crooked in there, and it jammed up and would not allow the gear to disengage the axles, so my front was stuck in 4wd even though the tcase was in 2hi and i had no inidicator lights.