Because you have electric diff lock. The part where you see the oil is where ther should be an oring
Has anyone done this on a 2012 450 TRV or other model with a four wire actuator? Would the same rebuild be possible? My actuator will not disengage from diff lock to 4wd. The actuator engages fine from two wheel to four wheel and then to diff lock. Thanks for any info.15. I applied RTV to the groove on the back side where the two halves of the cover come together (Fig. 14). Make sure to get a little extra around the wires (Fig. 15). Then I smoothed the bead and pushed the RTV into the hard to reach corners with my finger and the soapy water, also check the actuator O-ring (Part # 0423-498 which was replaced by 0423-892 and measures 5/16" x 7/16" x 1/16", should be able to find replacements at hardware or parts store for a fraction of dealer price) to make sure it’s not cracked or damaged (Fig. 15a). Flip the actuator and RTV the screw heads too (Fig. 16). Let the RTV cure for 24 hours. If you ever need to remove the RTV, just pour some isopropyl alcohol (rubbing alcohol 91%) on it and work it under the edge of the RTV. It should come off fairly easily once the alcohol gets under the RTV.
16. Reconnect the actuator wire back to the main harness. Turn the key on and flip the switch to 4WD. It’ll make it easier to install. Install the actuator into the differential and line up the front slot onto the front screw, but don’t tighten it yet. Install the screw on the back of the actuator and tighten it. This screw seats the actuator in the diff. Install the lower screw, then tighten it and the front screw. Bolt and zip tie the inner fender panel back on and you are done.
I did notice a couple things about the actuator while I had it apart. This may help with troubleshooting.
A. If it runs continuously, more than likely a gear has stripped out and you’ll need a new actuator. When a gear strips, the worm gear assembly can’t slide back and forth to trip the limit switches. The motor then runs constantly. If a gear is stripped, then it’s time for a new actuator.
B. The electronics in this thing are very simple. Should be able to look up parts to find replacements. They are probably readily available and inexpensive. There are three transistors (Q1, Q2, and Q3), two limit switches (SW1 and SW2), a relay (K1), three resistors (R1, R2, and R3), a larger diode (D1), two smaller diodes (D4 and D5), and finally the servo motor.
C. I added a pin out of the bottom of the circuit card assembly to aid trouble shooting. The K1 relay is a single pole double throw, which means it changes the direction of the servo motor by changing polarity of the power going to the motor's terminals depending on whether 2wd or 4wd is activated.
A. Limit switches (SW1 and SW2), Cherry Electronics Part # DH2CB1PA
About $2- 4 each, depending on where you buy them. Sager had the lowest price at around $2.
Data sheetB. Large diode (D1), International Rectifier Part # 50WQ03FN
Where to buy
Sager Electronics Price and Availability - Item Detail
Data sheetC. Relay (K1), Omron part # G8ND-2-DC12-SK
Where to buy
Mouser Electronics - Electronic Component Distributor 50WQ03FN for about $0.60
Data sheetD. Resistors (R1, R2, & R3), I'll update with exact part numbers and places to purchase later
Where to buy
http://www.onlinecomponents.com/omron-electronics_g8nd-2-dc12-sk.html?p=42305069 for $39 as of 4/20/2013
TodayComponents.com - Omron G8ND-2 DC12 SK Relay for $17 as of 4/20/2013
G8ND-2-DC12*Omron Electronics in stock as of 6/28/12 for $33 as of 4/20/2013
Resistor Values: R1 is a 1K ohm resistor. R2 and R3 are both 3.3K ohm resistors.
The physical size of the resistors need to be determined. I did not measure them when I had my actuator apart. Just measure the length and width and use the corresponding number for the size. Here is a chart of the different sizes.
Rectangular passive components:
- 01005 (0402 metric): 0.016 × 0.008 in (0.41 × 0.20 mm) Typical power rating for resistors 1/32 watt
- 0201 (0603 metric): 0.024 × 0.012 in (0.61 × 0.30 mm) Typical power rating for resistors 1/20 watt
- 0402 (1005 metric): 0.04 × 0.02 in (1.0 × 0.51 mm) Typical power rating for resistors 1/16 watt
- 0603 (1608 metric): 0.063 × 0.031 in (1.6 × 0.79 mm) Typical power rating for resistors 1/16 watt
- 0805 (2012 metric): 0.08 × 0.05 in (2.0 × 1.3 mm) Typical power rating for resistors 1/10 watt
- 1206 (3216 metric): 0.126 × 0.063 in (3.2 × 1.6 mm) Typical power rating for resistors 1/8 watt
- 1210 (3225 metric): 0.126 × 0.1 in (3.2 × 2.5 mm) Typical power rating for resistors 1/4 watt
- 1806 (4516 metric): 0.177 × 0.063 in (4.5 × 1.6 mm)
- 1812 (4532 metric): 0.18 × 0.12 in (4.6 × 3.0 mm) Typical power rating for resistors 1/2 watt
- 2010 (5025 metric): 0.2 × 0.1 in (5.1 × 2.5 mm) Typical power rating for resistors 1/2 watt
- 2512 (6432 metric): 0.25 × 0.12 in (6.3 × 3.0 mm) Typical power rating for resistors 1 watt
I removed the actuator pulled the cover cleaned all the diff oil
Out. replaced the 2 orings on the outer tube that goes into the front diff
And noticed a third seal the sits inside the tube that goes into the diff
It fits snug on the actuator pin in the front diff and is beveled. I can't find p/n for the seal. That's where all my oil was coming from
Try using a acid brush and appling acetone to the under side of the cover. Have the cover facing down. It will take a few applications of acetone but the cover will start to come off. Be patient!Sammy is your actuator the the one with electric diff lock? I have tried to remove the cover but it seems to be glued on. I have a 2010 450efi.