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Date:         Mon, 12 Oct 2009 09:55:42 -0700
Reply-To:     Bruce Todd <beeceetee@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Bruce Todd <beeceetee@GMAIL.COM>
Subject:      diff lock woes
Content-Type: text/plain; charset=ISO-8859-1

Okay - not to stretch this email into a long winded tale...I had my motor out of my 86 syncro westy this past summer to have a number of repairs completed. The main repair was to have the head gaskets replaced as I was having overheating issues. With the motor out, it was checked thoroughly for wear and then the top end was partially rebuilt. At the same time I replaced brake-lines, ps lines, ps pump, gas tank straps, coolant hoses, fuel lines and a few other odds and ends. I now have a stronger running motor that doesn't leak coolant or oil and idles very nicely. I also feel relatively more confident when taking my young family on longer trips.

Since buying the van several years ago, the rear diff lock has always been seized. Here was my opportunity to get this fixed with everything else when the motor was removed. The mechanic unseized the locking pin and put it all back together telling me that it took minimal pressure to engage the lock. This was all theoretical as when it came time to road test - the diff lock wouldn't engage. The mechanic told me to return when his shop was less busy and he would work on it some more. What does work is the green indicator dash light which permanently stays on once the vehicle starts whether the diff is locked or unlocked.

Twice I've taken off the actuator to check whether it works when I engage the dash knob and it does. Pulling out the knob elongates the stem of the actuator...pushing the knob in, contracts the stem. The diff lock has worked with the van on a hoist with the tires off the ground slowly being rotated and the locking pin being pushed with the actuator and with the help of a pry bar.

Yesterday I crawled under the van to unplug the wires which connect to indicator light switch - which is located above the actuator. Even with the plug disconnected the green dash light was still on. Does this mean that the diff lock pin is partially engaged or is there something else occuring? Why would the light stay on if the plug is disconnected?

This pretty much is the last thing that doesn't work on my van - and I'd love to get it working. Any words of wisdom would be most appreciated.

Thanks

BT


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