I am having trouble with the front diff engaging.
It blows the fuse , the thermal actuator works , but after a couple minutes the circuit blows the fuse.
Unpluging the actuator and the switch that shows the axle is engaged does not prevent fuse blowing.
Logic says I have a short in the harness, it's -25 out, and no shop. the the harness is good for as far as I can access it , but it has to have a short up top somewhere.
A simple fix would be to run a fresh wire to the front axle thermal plunger on a LED indicating toggle .and unplug the existing harness , so far I am ok with this,
Now, to monitor if the axle is actually engaged before taking off in 4x4 .This was always done with the factory light on the floor shift , but this is also controlled by the same circuit that blows.
It seems that the axle engaged switch is no more than a switch that sends power thru it to an indicator light on the floor.

Can I tap into the thermal plunger's power wire I am running to the switch that shows the axle is engaged , and add a LED indicator on the ground side switch wire ,beside where I will install the toggle ? Should be fine I think but ...will full power to the LED burn it out ? I don't think so , but unsure. I want to go ice fishing.

I will be using a 30 amp lighted toggle and a 30/40 amp relay .

 

In my experience the problem is usually the actuator itself. I've changed my trucks to posi lock cables for reliability.

 

It has a new actuator, the old one was slow to extend when I took it out, so I put in a new one.
Tomorrow I will wire in a toggle and relay and see what shakes.

 

Good news everything is working fine with the new controls for the front Axle. The axle engages with a flip of the switch , and as a side benefit I can have 2L if I ever want it. I never use 4L , but the option is there .

 

would you mind telling me how you did this? I'm having a similar issue with differential actuator

 

here is my 2 low