The short story: SUCCESS!!!
The long story:
I was finally able to get back to the truck to install the recently arrived ECU. However, it was not as simple as I had hoped:
- Installed the new to me VGRS ECU.
- Battery reconnected and the truck started. Same dash lights as before (stability control, traction control, and VGRS).
- Techstream revealed the traction control code was the same as before (C1289 - VGRS error), but the VGRS code changed to C1531 (VGRS ECU Malfunction)
- I assumed this was because the VGRS actuator had not been calibrated with the new ECU, so I followed the Service Manual and attempted to clear all codes and go through the VGRS calibration via Techstream
- Codes did not clear, and C1531 would not allow Techstream to start the VGRS calibration.
- Tried clearing the codes multiple times through Techstream with no success
- Much cursing ensued which did not clear the codes either...
- Remembered that the truck would need to be driven in a straight line above ~25 mph for about 30 seconds, to identify the "straight" value for the VGRS
- Drove around town for about 10 minutes with multiple 40 mph over 30 second straight sections
- Returned home, connected Techstream, tried to clear the codes - no success
- More cursing, and still no code clearing secret words...
- Decided to follow the calibration procedure using the SST check wire instead of Techstream
- Per the SM as C1515 was not a current error code, I created my own SST and performed the 3 way connection per the Service Manual. Interestingly the SST has 3 connectors (at leas in the picture I could find online), and the SM required CG and Ts to be constantly connected, but CG and Tc to be connected and disconnected 10 times within 20 seconds, then turn the steering wheel to the left >180 degrees, then 10 more connect / disconnect in under 20 seconds of CG and Tc - all under 1 minute.
- After an on / off cycle of the ignition, two things had happened - Techstream now also showed the C1515 error in addition to the already present codes, but the two traction control lights on the dash were no longer lit. Just the VGRS light.
- Used Techstream to clear codes again, and after the refreshed health check, only the C1515 code was present!
- Since the steering wheel was already centered from when I installed the new mid-shaft actuator, I skipped ahead in the SM to step 8 - "Adjust the actuator angle". reconnected CG and Ts, turned the ignition on, and the VGRS light now was blinking!
- Ignition off - remove the CG-Ts jumper - start the engine - turn left > 90 degrees - turn right 90 degrees - back to center for > 3 seconds
- VGRS light goes out!!!!
- Much celebratory yelling and family coming outside to see if I am ok...
- To be sure, drove around town for about 20 minutes and no warning lights!
So, after all this I am not sure if it was the VGRS ECU, the mid shaft actuator, or both that were non operable.
It was interesting that both the original C1567 and the new C1531 codes caused the C1289 traction control error and the lights on the dash, but the C1515 code seemed to suppress the traction control error and turn off the dash lights.
It also appears my Techstream / Mini VCI combination could not start the calibration cycle, but the manual wire method could. Wondering if another Techstream / Mini CVI version would actually ground and unground various pins on the port.
Anyway, I'll come back to this thread and update if the light reappears, but I'm calling this one good for now and am enjoying a warning light free dashboard!