Front e-locker troubles

[Uglibus]

I have got some issues with the front locker. First off the locker has been retrofitted to a 91 housing so we are not dealing with the factory wiring after the actuator. It was blowing fuses so I took it apart and found that is was corroded and very dirty. The shaft which goes into the axle housing was completely jammed from corrosion. I have cleaned it up and bench tested it with 12V. I can get the gear to turn easily in both directions. All grounds are good and have been cleaned. When the locker button (factory fog light button) is pushed I am getting a measured 11 V (battery is a measuring low for all the tests and no running) at the green with red tracer, green, and yellow. The only other wire is light green and it is 0 V. With the button in the unlocked position green with red tracer, green, and light green all measure 11 V. The yellow pulses. So I believe I am getting power to run the actuator and it is no longer bound up with corrosion, howver when all hooked up it refuses to move the gear. Any ideas?

 

[cruiserdan]

Is the dog clutch lined up?

 

[Uglibus]

The dog clutch? I have the actuator sitting an the floor attached to the wiring trying to get the gear on the actuator to spin. Is the dog clutch the part left on the housing which slides to lock.?!

 

[cruiserdan]

OK,

So you do not have the actuator reinstalled in the diff then. You are bench-testing the motor to see if the motor runs, no?

If so, do you have an FSM for a 93+ that shows you the testing method to use when supplying auxilary power for testing purposes?

 

[Uglibus]

So you do not have the actuator reinstalled in the diff then. You are bench-testing the motor to see if the motor runs, no?

I do have a 97 FSM but I since I don't have a factory plug it is more helpful to have wire colors than plug positions (PITA I am). When I connect the red green tracer and green (which are the thicker wires coming from the actuator to a 12v source I can get the motor to run forward and then when + and - are swapped it runs reverse. So the motor is turning the gear but when I have it hooked up to the wiring in the vehicle but out of the axle housing the button on the dash does not move the actuator gear in either direction.

 

[cruiserdan]

You need more bits than you have. The difflock ECU controls the actuator function. It is possible to mimic this with a relay bank. PM Theferg or check out his write-up about retro-fitting.

 

[Uglibus]

I have got that relay bank. It has worked without fail since the PO and installer did the work. That is until now.

 

[cruiserdan]

OK,

New set of parameters.


Did work, doesn't now.


Perhaps the actuator is not yet healed.

 

[Uglibus]

I could believe that! The only successful test I have tried and have gotten to make the gear turn is putting the 2 thicker wires to opposite poles of a 12v source. I have only proved that putting 12v can make the motor run and spin the gear in different directions. I would love other things to try as it is starting to make me insane trying the same test over and over hoping divine intervention will make the thing work again!!!!!!!!!!!!!!!!!!!!!!!!!!