Dorman 600-600 Instructions

INSTRUCTIONS
4WD ACTUATOR
WIRING HARNESS
600-600
BEFORE YOU BEGIN:
• Always wear proper safety
equipment when performing repairs.
• Ensure at your point of purchase
that this part fits your exact
vehicle configuration.
• Reference the appropriate service
manual for your vehicle. If you do
not have a service manual, and do
not have the training or experience
to perform the necessary
procedures correctly, seek the
services of a qualified technician.
NEED HELP?
Please call our Technical Support
team for assistance from our team of
certified automotive experts.
1-866-933-2911
© 2022 No reproduction in whole or in part without prior written approval.
600-600_Instructions
NOTE: You will need to be familiar with
electrical circuits to successfully install
this component. Consult the appropriate
factory service manual for specific
installation procedures.
INSTRUCTIONS
STEP 1:
If equipped, remove the front differential
carrier shield.
STEP 2:
Clean the area surrounding the actuator to
prevent the entry of debris. Disconnect the
electrical harness.
STEP 3:
Remove the front axle actuator.
STEP 4:
With the flat side seated against the shift fork,
install the spacer from the wiring kit into the
axle tube.
STEP 5:
Install the actuator motor and tighten until the
shoulder of the actuator seats against the axle
tube. Do not overtighten.
IMPORTANT: If binding occurs before the
actuator is seated, remove the actuator
and reseat the spacer by pushing on the
spacer with a screwdriver, then reinstall
the actuator. On K3500 models with cast
iron axle tube, casting flash may contact
the edge of the actuator. If the actuator
will not seat correctly, remove the flash
using an appropriate tool.
STEP 6:
Attach the service harness connector to the
actuator and connect the 2-pin connector to the
mating connector at the axle.
Dorman Products, Inc. Corporate Office and Customer Service: 1-800-523-2492.
Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible
circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to
do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage
or personal injury. Certain motor vehicle standards and performance requirements may apply to your motor vehicle (such as Federal Motor
Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such
standards and that you do not disable any motor vehicle safety feature.
STEP 7:
Route the wiring harness on the right side of the
vehicle. There are a couple of different ways to
route the harness. There is a bracket that the
harness can be routed along and attached to. The
new harness can also be routed along the existing
harness. Route circuit 241 (brown) over the top
and to the left of the transmission. Attach the
harness either to the bracket or to the existing
harness using plastic ties.
STEP 8:
Splice the brown wire on the new actuator to the
brown wire on the vehicle side.
IMPORTANT: The new fast axle actuator
requires only one splice.
NOTE: Connections must be watertight in
order to prevent water from entering the
circuit and damaging components.
STEP 9:
Verify that the system is operating correctly. You
should hear the actuator motor operate when
shifting the transfer case.
PAGE 1 OF 3