Chevrolet Repair: 4x4, shaft coupler, 4x4 van

Question
Van, I'm having the same problem as Rick but the fuse doesn't blow until I put the transmission in gear. I have a 94 gmc 454.  I have checked the actuator and it works I also have free movement of the shaft coupler.  So is it possible that the thermal actuator is really bad?  Thanks for any ideas you can give me.

Joe

Answer
Hi Joe,
I need to know what you mean by put the transmission in gear.

If you mean you shift the transfer case and all is well, but then put the main transmission in gear blows the fuse, I would look at the wires going to the switch on top of the transfer case, under the passengers seat area. The torque of the engine could be rocking the engine and transmission on the mounts, and squeezing one of the wires against the frame or body, shorting it out.

If the actuator is bad, they are usually burnt open, but if it were internally shorted, I don't think it would wait for the transmission shift. It would blow the fuse right away.
You could test that by unplugging the actuator, and with a good fuse in place, shift it, and see if the fuse still blows.

Van