4WD Actuator Removal
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Joined: Mar 2002
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4WD Actuator Removal
After a couple years of having to periodically un-freeze my 4WD Actuator piston I finally decided to replace the actuator. I made an attempt at it yesterday, but found that the brass sleeve is literally fused into the aluminum housing it protrudes through.
Has anyone had a similar issue? I tried PB Blaster and heat, but no luck so far. There is not much room to work with to hammer the sleeve out. I am thinking of cutting the actuator at the sleeve where it enters the aluminum housing to acquire some more room. If I cannot get it out, I will resort to drilling some holes through it to weaken it enough and take it out in pieces if necessary.
Here is a link to the actuator I have as a replacement. It has the same brass sleeve:
More Information for DORMAN 600300
Any and all advice appreciated.
Thanks......
Has anyone had a similar issue? I tried PB Blaster and heat, but no luck so far. There is not much room to work with to hammer the sleeve out. I am thinking of cutting the actuator at the sleeve where it enters the aluminum housing to acquire some more room. If I cannot get it out, I will resort to drilling some holes through it to weaken it enough and take it out in pieces if necessary.
Here is a link to the actuator I have as a replacement. It has the same brass sleeve:
More Information for DORMAN 600300
Any and all advice appreciated.
Thanks......
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Senior User
Joined: Mar 2002
Posts: 101
Likes: 1
I thought I would answer my own post in case others ran into the same issue. I ended up cutting off the old 4WD actuator (reciprocating saw) on each side of the aluminum housing it is inserted through. This will leave you with a brass sleeve and the actuator rod inside it. The actuator rod will slide right out. You can then drill out part of the brass sleeve (I used a 1/2" drill bit), which leaves about 1/8" thickness of sleeve. I then took a hack saw blade and scored through the brass down to the aluminum in two places about 1/8" apart. I could then punch that piece out with a hammer and screwdriver. I scored one more 1/8" piece to attain about a 1/4" opening in the sleeve. I was then able to collapse the sleeve on to itself (using a hammer and screwdriver again) to pop it out of the aluminum housing.
Hope that helps someone in the future
Hope that helps someone in the future
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