4X4 not working

Tiny
EXCIDO
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Hi. Sorry for the late reply.
I switched the truck out of 4x4 and it went back into 2x4 no problem.
Again when I switch back to 4WD the fuse pops.
I’ve unplugged the actuator (as suggested) and the fuse still pops the moment I put a new (20 amp) fuse in (actuator unplugged).
I put in a 25 amp and it popped the first time, then held the second time. I plugged the actuator back in and has allowed me to go back in to 4x4. That suggests the actuator is still ok and the short is elsewhere?
Also, the lights of the rocker switches are lighting up ok, but then they go out once it’s in 2x4 or 4x4 or are intermittent.

Other suggestions appreciated. Thanks.
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Sunday, February 10th, 2019 AT 4:48 PM
Tiny
EXCIDO
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Also,
When the fuse blows the lights on the rocker switches display an odd lighting scheme - image. Three lights are lit. The 4x4 low, the 2x4 and a red neutral light is indicating! This is when the truck is now in 2x4 and the fuse is blown.

Help.

Thanks.
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Monday, February 11th, 2019 AT 3:21 AM
Tiny
KEN L
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It sounds like the rocker switch is shorting out, lets try a new one to see what happens.
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Monday, February 11th, 2019 AT 10:05 AM
Tiny
EXCIDO
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Hi. Sorry for long delay. Takes two weeks to get parts out here in the middle of the Pacific.
So, replaced the rocker switch. Nice to see 4x4 and 2x4 actualy light up, but unfortunately still popping fuses. That is, when I switch from 4x4 back to 2x4 it switches but then the fuse (number 2 pops).

To date I’ve tried unplugging the actuator and rocking the switch (pops fuse) and replacing the rocker switches (still pops fuse).
As above, when the fuse pops, three lights are lit. The 4x4 low, the 2x4 and a red neutral light are all indicating.
When I replace the fuse, it immediately pops a new one (20 amp). I have then placed a 25 amp fuse and sometimes it holds and I can switch back into 4x4 where it will hold for weeks - until I switch back into 2x4 and the pop! All the fun starts again.

Any further suggestions of what I can test?

Thanks for your patience.
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Tuesday, March 5th, 2019 AT 4:54 AM
Tiny
KEN L
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Down at the encoder can you unplug it and then replace the fuse to see if it still pops?
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Tuesday, March 5th, 2019 AT 10:10 AM
Tiny
EXCIDO
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I think we did that already. I have unplugged the encoder and pushed the rocker switch and it still popped the fuse.
I have not done that again with the new rocker switch and will try that.
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Tuesday, March 5th, 2019 AT 4:37 PM
Tiny
EXCIDO
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Okay. When the actuator is unplugged the fuse still pops when the rocker switch is pressed from 2x4 back into 4x4. This is the same weather the actuator is plugged in or not.
That would suggest the actuator is still good and I have just replaced the rockers switches. So it’s good.

What else to test?

Thanks.
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Thursday, March 7th, 2019 AT 9:29 PM

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