4WD fuse keeps blowing

There is a transfer case switch located on the top left of the unit I would start there. Here is the wiring diagrams for the transfer case.

If the front differential actuator shorts out on these trucks. Try unplugging the 2 wire plug that goes to the front diff actuator and see if the fuse still blows, if it does not then you know the actuator is no good.

Check out the diagrams (Below)

Please let us know what you find. We are interested to see what it is.

Cheers

Yes its located on the front axle. It has 2 wires coming out of it. The actuator screws into the front diff, it has a huge 1 1/16 spot for a wrench or you can unscrew it with a big pair of channel locks.

They have since updated the part because of so many problems. The new kit comes with a wiring harness that has to be installed and I think it cost about $150-175 for parts. If you look around you might be able to find the exact one you have that will unscrew and plug right in for about $100