2008 commando actuator removal

Tn. Renegade Rider · September 16, 2014

have a new actuator to install, but can't seem to get the old one off. Have removed the screw and can wiggle it freely, but cant get the tube and o ring that go to into the differential to come free. trying not to break it off in the process. Any suggestions besides more brute force?

Tn. Renegade Rider · September 18, 2014

oppps.....tonight I found a screw still holding it in place, that was hidden. Came off fine after that.

kenfain · September 18, 2014

Well done! ... I usually break something, when trying to fix stuff. Hope I goes smooth from here. Sorry we couldn't be more help.

Tn. Renegade Rider · September 18, 2014

Yeah, I even amaze myself sometimes, with my stupidity.

bmoody4550 · January 20, 2020

Hey there,

What process did you go through to figure out you needed a new part?

I have a 2006 650 Commando and 4wd is not engaging. I pushed the button on the dash. That is the extent of my checking out what the problem is so far.

I realized the 4wd wasn't working when I went to move the machine and got stuck in a little bit of snow and the front wheels were not moving.

I am still re-habing the machine and this would be the next on the list.

Thanks for any info.

Tn. Renegade Rider · January 21, 2020

Its been so long ago that I can't remember exactly how I diagnosed that it was the actuator. I think that I just looked at everything else and it all looked good. But when I took the actuator off it was corroded and looked terrible.

bmoody4550 · January 22, 2020

Ok thanks for your response. If I can get to 4wd I'll be happy

kenfain · January 22, 2020

I'd troubleshoot the switch first. Wiring second. Then, obviously there's the actuator.

bmoody4550 · January 23, 2020

From other posts I have seen sounds like there should be power to the actuator when the switch is in the 2wd position and no power in the 4wd position. Is this correct?

Default position should be 4wd?

If I do take off the actuator to look at it closer is there parts going to go flying (springs ect)? Would you suggest takling the hood off to be able to see from above?

Hood is on now and I would try working on it from the wheel well.

Will I need anything new like gaskets to be able to re-install?

Thanks

Bill

bmoody4550 · January 31, 2020

Well I have power to the switch and down to the actuator.

I went to take out the actuator unit and when I took out the screw through the firewall it backed out but was against the wall so i couldn't move it to remove it.(up against the firewall).

But as I was looking at it, I must have brushed up and turned the tire which turned the other tire.

The pin must have come out allowing the 4wd. which I am happy with.

I put the two screws back in and then lost the 4wd. I backed off the screw coming through the firewall and must be enough to allow it to go back in 4wd.

I guess the short story is the actuator is toast but I can go in and out of 4wd by turning the screw.

Anyone with more thoughts on this subject?

Thanks

Bill

kenfain · January 31, 2020

Be aware that long term use of 4wd on hardpack surfaces, or especially pavement will cause damage to the front 4wd components. Other than that it sounds good.