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I got my shop manual set on ebay from FAXBOOK. Has been well worth it.

You said it gets "really" warm. If this were a thermal actuator it would get warm but I recently read that thermal actuators are hard to come by. Notice if there is a 2 pin connector above the actuator sticking out of the diff and if there are wires connected to it. If there is, that...

A hunting rig is exactly what I had in mind when I bought my '96 a few years ago. Here is a shot of it out in the woods muzzleloading this past weekend. Also that is my nephew's Blazer behind it.

The encoder motor is what puts the transfer case into 2WD/4WD-HI/4WD-LO when you press the selector button. The "encoder" switch on top of the transfer case closes when the transfer case is placed in one of the 4WD modes to provide power to the actuator to engage the front differential and...

Storage???? My Tahoe and I live for this.

BTW replacing the actuator, if you are using the same type that you have, is about a 10 minute job. Unplug it, unscrew it from the differential, screw in the new one, plug it back in. $600 seems a bit hefty since the actuator itself is in the $90 - $150 range depending where you get it, but...

The dealer or the local parts store.

Not sure what you mean that it doesn't connect. If the relay sound you are hearing is inside the cab, that would be the TCCM trying to activate the 4WD. When you select 4HI, does the light come on (flash) and go off again or does it stay flashing? There are basically 5 parts...

Wow...alot less than I paid for mine, to use as my second battery, and I don't have the aluminum bractet.

I tapped into the power for the mirror (compass) so the detector would operate with the key.

Took me awhile but I wanted to go out to the garage and locate the device to get the part number (along with Christmas and year end stuff to deal with). It is actually a 240A isolator. I purchased this from Wrangler Power Products (but can't find it on their website now) and have never used...

I recently finished my dual battery install. In the beginning my intent was to use a diode setup and purchased one (200A because my alternator is 180A) but ended up going with a relay setup because that diode device took up so much room. It is a relatively simple task to accomplish this if...

This would indicate that the transfer case is engaging but, in itself, doesn't mean the front diff is. If it is the proxy switch (thermal actuator) or the contacts (motor actuator) and the system is engaging (transfer case and differential) then as long as you can put up with the blinking...

I don't need to remove my skid plate to see the front differential.

I am curious, which positive and negative cables are you referring to?

The actuator sticks out the passenger side of the front differential. It is screwed into the diff and is pretty easy to get out. The thermal actuator diff has a 2 pin connector above the actuator. Refer to TSB 76-43-01A for more info. To listen what is engaging (or not) have someone...

To reset the controller on my 96 I disconnect the negative battery cable. I have been told it takes about 30 seconds but I have never timed it.

Other than the "click" that goes on under the dash when you press the 4WD switch you may hear 2 "clunks": the transfer case servo motor and the front differential. If the light is flashing this can be an indication that the controller has not detected the system is engaged. In the case of...

If your 4WD light is flashing then 4WD is not engaged. Where is the "clunk" coming from? Or is it a "click" under the dash? Issues with the 4WD can be (I don't know if this is the proper order of probability): the actuator, the transfer case switch, the 4WD selector switch, the...

After replacing the fuse did you get lights at the switch? The clicking you heard under was the 4wd controller. If you are still not getting any lights then the issue is most likely not the actuator since the switch lights should flash at you until the 4wd engages. It could be the switches...