re
 Even with
the plug disconnected the green dash light was still on.
----- Original Message -----
From: "Bruce Todd" <beeceetee@GMAIL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Monday, October 12, 2009 9:55 AM
Subject: diff lock woes

> Okay - not to stretch this email into a long winded tale...I had my motor
> out of my 86 syncro westy this past summer to have a number of repairs
> completed.  The main repair was to have the head gaskets replaced as I was
> having overheating issues.  With the motor out, it was checked thoroughly
> for wear and then the top end was partially rebuilt.  At the same time I
> replaced brake-lines, ps lines, ps pump, gas tank straps, coolant hoses,
> fuel lines and a few other odds and ends.  I now have a stronger running
> motor that doesn't leak coolant or oil and idles very nicely.  I also feel
> relatively more confident when taking my young family on longer trips.
>
> Since buying the van several years ago, the rear diff lock has always been
> seized.  Here was my opportunity to get this fixed with everything else
> when
> the motor was removed.  The mechanic unseized the locking pin and put it
> all
> back together telling me that it took minimal pressure to engage the lock.
> This was all theoretical as when it came time to road test - the diff lock
> wouldn't engage.  The mechanic told me to return when his shop was less
> busy
> and he would work on it some more.  What does work is the green indicator
> dash light which permanently stays on once the vehicle starts whether the
> diff is locked or unlocked.
>
> Twice I've taken off the actuator to check whether it works when I engage
> the dash knob and it does.  Pulling out the knob elongates the stem of
> the actuator...pushing the knob in, contracts the stem.  The diff lock has
> worked with the van on a hoist with the tires off the ground slowly being
> rotated and the locking pin being pushed with the actuator and with the
> help
> of a pry bar.
>
> Yesterday I crawled under the van to unplug the wires which connect to
> indicator light switch - which is located above the actuator.  Even with
> the plug disconnected the green dash light was still on.  Does this mean
> that the diff lock pin is partially engaged or is there something else
> occuring?  Why would the light stay on if the plug is disconnected?
>
> This pretty much is the last thing that doesn't work on my van - and I'd
> love to get it working.  Any words of wisdom would be most appreciated.
>
> Thanks
>
> BT