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Ask GM Tech (Cam) Your Own Question
GM Tech (Cam)
GM Tech (Cam), Chevy Technician
Category: Chevy
Satisfied Customers: 29427
Experience:  GM Grand Master Technician 2007. 14 years experience.
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1994 chevy ck 3500 blowing fuses when put into 4wd, 25 amp,

Customer Question

1994 chevy ck 3500 blowing fuses when put into 4wd
JA: Do all the fuses have the correct amperage for the circuits they're in?
Customer: 25 amp
JA: Are you fixing your 3500 yourself? What have you tried so far?
Customer: removed the transfer switch to see what it does. Does not blow fuse when unplugged. When I press the ball the pins are shorted together, but I don't know what to expect. Resistance or not.
JA: Anything else you want the mechanic to know before I connect you?
Customer: I can't find the wiring diagram for the truck. The clinton manual does not contain 4wd diagram.
Submitted: 2 months ago.
Category: Chevy
Expert:  GM Tech (Cam) replied 2 months ago.

Hi there, I am Cam. "

This fuse blowing is a result of the front axle actuator. The pins in the switch on the transfer case only send power to the thermal actuator on the front axle, causing it to extend and engage the front axle. More often than not, the thermal actuator fails and causes the system to short out when you engage it.

25 Amp is the proper fuse, so remove the actuator on the right side of the axle and replace it.