How Do I Remove Center Diff Lock Actuator

[uHu]

I think you have understod the system, and the possible problem.
I have replaced the actuator several times, with the cdl open. As long as the mechanical parts in the gearbox are in the fully open position, and the actuator is in the open position, it shouldn't be a problem.
Iirc, you can put that loose cogwheel into the box, and turn it, and thereby feel what's happening inside. But I would do that only if I suspect that the locker is somewhere mid-travel.

Once, when replacing the second burned out actuator motor, I thought it could be a problem of the motor never getting to it's end position because of a mis-alignment of the actuator and the gears inside -- but it turned out to be a cabling fault, grounding just the right cable to make the motor trying to work beyond it's limits. In that respect it's a bit of a silly design with the end-stop-switches relying on a relay which is several cable-meters away. A burned relay-contact could also burn out the motor.

 

[WomblingFree]

All done. Having driven the truck a few thou Km's with the CDL dead, I assumed it was in its fully unlocked position.
I plugged the replacement motor into the wiring but not attached to the transfer case. After cycling the motor a few times to ensure its in its unlocked position I bolted it onto the transfer case and hoped for the best.
Went for a drive and can't notice any difference in driving with it locked or unlocked but then its just had a new steering rack fitted which has the most unbelievably light touch, you could steer it with your tongue, so this might be masking the effect a bit.
Chocked the car in the driveway with the handbrake off, transmission in neutral. Jacked up one front wheel and ensured it would rotate freely in CDL unlock then pressed the CDL button, wheel locks nicely.

Guess its working but it sure doesn't feel like it in the steering.

 

[uHu]

Congrats.
CDL isn't felt much on the steering, but you hear it from the wheels when cornering.
RDL does hamper the steering much more, not to mention FDL.