My CDL locker actuator has been flaky and now no longer works. I tried troubleshooting and found that both the electric actuator is burned out and I have some wiring issue behind the dash. Seems like its pretty common to have the actuator fail, but with the combination of a wiring issue, I started to not really want to fix the electric actuator.
I started researching options to fix this and came across these (link) air actuators from KRAE 4x4 in New Zealand. I reached out and got a quote for ~$900 USD. This seemed like lot and I thought I could build one.
I found an air actuator similar to what they used:
These seemed similar to what KRAE used and I was able to get them for about $50. They are basically two pistons with a rack and pinion setup. I then had to adapt the actuator to the transfer case bolt pattern. I scanned the transfer case actuator and then drew up a quick mount. Quick CNC part
Making the shaft. Didn't get photos of the baseplate in the CNC.
If anyone is trying to do something similar, the pinion spur gear that interfaces with the rack that moves the CDL locker in the transfer case is an 18 tooth, mod 1 spur gear. The bearing surface is ~21mm. Locking is counter clockwise, unlocking is clockwise.
All installed. Works well, actuates at as low as ~40 psi. Uses a standard 5/2 valve.
If anyone else is in a similar boat and doesn't want to deal with electronics, I can send over measurements. Hadn't seen anything like this on here and thought it was cool. I've got access to a machine shop so this was a pretty quick and cheap fix.
I started researching options to fix this and came across these (link) air actuators from KRAE 4x4 in New Zealand. I reached out and got a quote for ~$900 USD. This seemed like lot and I thought I could build one.
I found an air actuator similar to what they used:
These seemed similar to what KRAE used and I was able to get them for about $50. They are basically two pistons with a rack and pinion setup. I then had to adapt the actuator to the transfer case bolt pattern. I scanned the transfer case actuator and then drew up a quick mount. Quick CNC part
Making the shaft. Didn't get photos of the baseplate in the CNC.
If anyone is trying to do something similar, the pinion spur gear that interfaces with the rack that moves the CDL locker in the transfer case is an 18 tooth, mod 1 spur gear. The bearing surface is ~21mm. Locking is counter clockwise, unlocking is clockwise.
All installed. Works well, actuates at as low as ~40 psi. Uses a standard 5/2 valve.
If anyone else is in a similar boat and doesn't want to deal with electronics, I can send over measurements. Hadn't seen anything like this on here and thought it was cool. I've got access to a machine shop so this was a pretty quick and cheap fix.
