Posted by Traveler on January 25, 03 at 11:34:32:
In Reply to: K1500 4 X 4 Actuator Upgrade / Brown Wire? posted by Tim on January 25, 03 at 09:19:49:
: Can anyone please tell me where I splice in the brown wire? Thanks in advance and have a great day!!
from my '95 repair:
Posted by Traveler on December 06, 01 at 10:01:48:
I had retrofit the electromechanical actuator with its new harness and wanted a
good connection point for the "dangling brown wire" that results from the
harness. I had measured the current draw and saw a couple mA on the wire even
with the 4WD off, so a direct battery connection was not desirable.
Finally cracked the 95 manual and found the circuit. The power to the thermal
actuator came from a tap "hot in run" thru fuse 24 (lower right fuse in panel on
drivers side dash end) and on through a brown wire to the transfer case switch
(actuated by the lever) and finally to the actuator. Other side of actuator is a
black ground wire (only 2 terminals).
Accessing the brown wire underneath was difficult so I looked for access to the
output of fuse 24 under the dash (in-convenience center). After some probing,
the fuse 24 output (bottom terminal) feeds a contact point in a group of three
unused male terminals. The group is labeled Drk Grn underneath the slot and
occupies the lower left side of the panel. The rightmost pin is the one fed from
fuse 24.
Next it was time to drill a hole in the firewall to pass the brown wire. Ended
up with a spot about an inch below the hydroboost mounting pad accessible from
both sides. I'll need more and larger holes for future mods and the same spot
will work. 3/8 hole with grommet gives 1/4" wire space. I had to lengthen the
wire about 8" to reach the terminal.
The pins in the in-convenience center are very small and I did not have the
proper female lug, but found I could use a larger lug and just capture one side.
If I find the right lug, I'll change it out later.
Misc Items:
The transfer case switch also feeds an active low signal to the PCM for auto
trans control. The front axle switch that closes when the actuator has moved
feeds an active high signal to the ABS system as well as the 4WD indicator lamp.
Also feeds a relay in 3500 series only that drives a T-case synchronizer.
Looking at the 99 manual for reference to the EM actuator, it has 5 terminals:
Power from fuse 24 on a brown wire, black ground wire, internal switched signal
feeding the VCM (blk/wht), active low input from T-case switch to command it
"on" (gry/blk), and an unused pin labeled "man".
Hope this helps.