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This past weekend i went on a little drive in the mountains with my newly bought 1991 Chevy S10. 4×4 was working great and it had no problems. About 2.5 hours in i got stuck in a small valley between ridges. I couldn’t get up either side. I had one of my buddies get out and see if both front and back where spinning as it seemed it was acting like it was in two wheel drive. He said the front wasnt. I then noticed the light on the 4×4 turned off ( was stuck on when i bought) even though the transfer case was stillin 4H. Thenext day i had the truck pull home and i checked the first thing i read about on the forums,the vacuum actuator. It wasnt working. Followed the line and the exhaust had melted a hole through it. so i thought sweet easy fix and went to auto parts store and got some vacuum line for cheap. as i ran the new vacuum line to the vacuum switch i got confused on witch it went to as all plugs on switch where plugged in. i got online and found the routing for the lines. Turns out the previous owner had jumped the switch, had the vacuum lines routed right next to the exhaust and ran the actuator vacuum line directly to a vacuum source. So the front axle was always engaged.I was blown away at it. i reran the vacuum lines away for the exhaust and to the correct spot and tried the 4×4 again. this time stillnothing and the light on the 4×4 didnt turn on. I then went back to the auto parts store and bought a switch that screws into the transfer case connected the vacuum lines and tried again. Nothing. I have tried everything i could think of. What else is there to check? Anyone else have the same or similar problems?
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🙁 I am sorry that you are having this problem. You may get an answer on here from the members, and I hope you do. You may want to google”S-10 forums” and go to a Chevy s-10 forum to see if they can help also. I used to own a 98 S-10, but it was a 2×4 drive and I also looked in my now old Haynes manual and it started at 94. I would look to the S-10 forums and see if they can give you some answers. Good Luck.
🙂 I see you went over to the S-10 forum and posted a thread over there. I would use the search box on that forum and type in “91 Transfer case problems” and see what comes up. I bet that someone over there knows what is wrong. Good Luck.
The 4×4 still doesn’t work I’m going to try and look for vacuum leaks next.The actuator still works. I tested it by hooking it up to direct vacuum. Will keep you guys updated. Thanks for your help
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