Utility ATV repair and maintenance & Troubleshooting Place your Utility ATV Repair and Maintenance questions/thoughts here... *not performance*

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Old 05-26-2012, 10:20 PM   #1
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Exclamation Diff actuator repairable?

just took the actuator out of my 2010 H1 Mudpro 700 because it was stuck in 4X4, it was full of oil, I assumed it was some special di-electric (not sure on the spelling lol) oil, so I saved it. plugged it onto the bike with the cover off and everything worked great, put it all together (with what I thought was special oil for it back inside it) installed it, it was switching great for about 2 switches and bang it's stuck in 4x4 again and will not change to 2x4 or 4 wheel lock, after some investigation on the web I now think it's supposed to be dry inside and the gear oil leaked in from the diff...??? the dealer told me last year it was a $400 part, I would like to fix it cheaper if I can, I am great with repairs and backyard mechanics what should I look for to stop this oil leaking into the actuator?
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Old 05-26-2012, 10:23 PM   #2
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How full is your diff? Pull the actuator off and let it dry out
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Old 05-26-2012, 10:51 PM   #3
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www.mymowerparts.com free downloadable service manual. Can help with questions
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It's mind over matter,If you don't mind,
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No Boost No Bottle
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Old 05-26-2012, 11:01 PM   #4
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My 2010 Mudpro did the same thing, but I got it covered under warranty. Do you have any warranty left?
There are no replaceent parts for inside the actuator from Cat at least. Someone on here a week or two ago had access to the circut board inside the actuator I think? And yes, it's suppoed to be dry inside the actuator. The new upgraded actuator is P/N 1502-909.

Last edited by Winch_Warrior; 05-26-2012 at 11:09 PM.
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Old 05-26-2012, 11:18 PM   #5
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There must be some sort of seal in there. If not something is cracked?
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Old 05-26-2012, 11:23 PM   #6
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Diff actuator repairable?-imageuploadedbytapatalk1338092589.382847.jpg
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It's mind over matter,If you don't mind,
It just doesn't matter

No Boost No Bottle
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Old 05-27-2012, 08:44 AM   #7
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Thanks everyone,
Blissman, I will have to check to see how full the diff is today, maybe water got in and over filled it?
doorfx, Thanks for the link and the photo, they helped me quite a bit, all I could find at the link were mostly service bullitens, but I did find a great blow-up of the picture you posted in the parts manual section.
Winch_warrior, unfortunately my warranty ran out a while ago. Last time I took it in to replace a broken axle I thought it was still covered, they called me and quoted me $3000 worth of work, I said put it back together I'll fix it myself (I'm a great backyard mechanic LOL) I'll take it apart again and look for a bad seal.
Puffyklipper, I will take it apart today looking for a bad seal somewhere

Thanks everyone I will keep you posted when I figure this out.
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Old 05-27-2012, 08:52 AM   #8
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OOPS doorfx I just went back to the link and realized I clicked the wrong directory, I found the service manual thanks!!
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Old 05-27-2012, 08:00 PM   #9
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ok, quick update, I took the actuator off, drained all the oil out of it, sprayed a can of electircal contact cleaner in it, let it dry, put it back together and installed it, works like a charm, so now I have to get a front diff rebuild kit to stop the leaks in the diff. Point is, when the dealer tells you that the $400 part they want to replace is not repairable, it is not always the case (not to put down the honest dealers). because I did this myself I found that the part they wanted to replace was not the problem but my front diff is the main cause, what do you think the odds are that my dealer would have cleaned up the actuator and just repaired the diff for me? I doubt very much he would have, he would have charged me for the actuator, and the diff kit, plus labor. (I know time is money, and safety is a factor to dealer's, I'm just commenting on how I saved money by doing it myself) (I'm rambilin lol sorry)
Anyway I will get a diff rebuild kit, and thanks to the service manual link doorfx sent me shouldn't be too bad of a job!

P.S. Ha in the process I decide to clean the rad (plan on relocating it up by the snorkel) and find a pin hole in it, now to get some stop leak lol

Last edited by hotelcali4nia1; 05-28-2012 at 03:55 AM.
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Old 06-30-2012, 11:29 PM   #10
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The actuators are repairable, Cat just doesn't want to pay to train their techs how to rework circuit cards nor come up with the proper rework tools. It's cheaper for a Cat tech to spend 20 minutes replacing an actuator, just not cheaper for us. You just have to have a little skill with a soldering iron, determining which parts inside are bad and being able to get replacement parts. Finding some of the parts has not been easy. I've been trying to find the relay that is in the actuators, but the OEM is either out of stock on most sites or you have to have a minimum order for a bazillion parts. I think I may have found a substitute relay though. I've got to do some more research on the specs. I'll post the info in my actuator dissasembly thread.
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