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This is a quick "how to" for repairing a newer electric diff lock actuator. Mine had a broken plastic cam on one of the gears that I was able to epoxy. If yours has water/mud infiltration you can clean the circuit board with electric contact cleaner.

No guarantee it will work again but it's worth a shot as they are $300 for a new one. AC states it is not a serviceable part so don't expect to be able to buy parts for it.
What you will need;
#o Phillips
#2 phillips
2 small flat blades
1 pick
Needle nose pliers
Goof off ( or equivalent)
Rtv silicone
Epoxy ( optional)

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Start by removing it from the machine. The testing procedures and re and re are in the service manual. Download a free service manual here Country Cat Home
Once it's on the bench remove all twelve screws holding it together.

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It is glued together with some type of sealant so you will have to carefully pry it apart using some type of adhesive remover. I used goof off. Take your time!!

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Once you have it apart , remove the two plastic gears noting orientation.

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Next remove the 4 #0 screws holding the diff lock rod boot in place

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Then remove the pin that holds the diff lock rod in place. Then carefully remove the rod and the spring. It takes some bending and tweaking but it will come out. Just don't damage the board or limit switches.


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Next unhook the plug that is connected to the circuit board. It's tough but with patience it will unplug.

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Now you can remove the circuit board and clean it up if that's your issue. You will have to work it up and over the 4x4 mechanism to get it out.

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The 4x4 mechanism can be removed by bending the main gear holder slightly.

ImageUploadedByTapatalk1415765801.217294.jpg ImageUploadedByTapatalk1415765833.451012.jpg

Mine had a broken cam as mentioned.

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I epoxied a nail into the center of the broken piece then epoxied it back together and it is super strong

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Now you can put everything back
together in the reverse order using white lithium grease on the gears. Use RTV silicone or something of your choice to reseal it. I used caulking remover to get all the old factory sealant off first. I also siliconed the boot on the diff lock rod. It works great again !
 

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Here are a few pics of the limit switches etc.
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Discussion Starter #8
This works good for cleaning up the board
ImageUploadedByTapatalk1415881818.283303.jpg
 

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Actuator 4x4 lock rod boot

Has anyone found a good replacement for the boot seal? Got everything cleaned up and ready to assemble, but i need a new boot.
 

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Discussion Starter #11
Get the updated one and fill it with silicone. That's all I got lol
 

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Hello,

i'm an italian member of this forum;
first of all, i'm sorry for my english...

My experience with this actuator? Full gear oil within it naturally...

I cleaned it, and it works fine.

But I'm looking for the seal.



Someone tell that Arctic cat not sell it. Is this information right?

Actually i don't find it in the parts catalog.

Someone can tell me the procedure for solve the problem?

Thank you for answer.
 

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Thanks for the bump! I was about to go looking for this post
 
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