Chevrolet/GMC Chevrolet/GMC Posi-Lok Installation Instructions

Pre-Installation Information Special Tools
T-30 and T-40 torx male drivers (required only on 1994 or newer vehicles); Unibit #3 for 9/16” hole; 7mm and 10mm socket drivers; 3/32 Allen wrench
1. This is a universal kit designed to fit all T-10/15’s. You will have some parts left over. While installing, you will need to study the pictures and use good judgement.
2. Road test 4WD system to be sure there are no internal mechanical problems with the transfer case or front differential assembly. Also test and repair indicator lights, as may be required. It is a good idea to inspect fluid for metal and change fluid per owners manual.
3. Set emergency brake, place automatic transmission in park, or place standard transmission in gear and transfer case in 4WD.
4. Raise the right front wheel allowing the right front wheel (only) to rotate freely.
5. Squeeze vacuum actuator (with fingers) to engage front axle while rotating right front wheel. If wheel will not stop rotating, refer to #3 above or you may have a cable or internal differential problems. Normal O.E.M. clutch cable travel will be approximately 7/16” to full lockup.
6. Locate source of vacuum to transfer case switch and plug off as close to engine source without disrupting any other vacuum requirements. Use the 3/16” vacuum cap which is supplied.
7. Before drilling always check for electrical wires, hoses, etc. You may want to disconnect the negative terminal from the battery. Refer to the vehicle owners manual.
8. Never allow sharp bends or kinks in the cable and keep away from heat and moving parts. Leave easy access to other service items. Use tie strap.
Please note the following:
•If you have a 1983 through 1988 – Use pages 1, 2, 4 & 5 (Actuator Beside Battery)
•If you have a 1988 through 1994 – Use pages 1, 2, 4 & 6 (Actuator Under Battery)
•If you have a 1994 and newer – Use pages 1, 2, 3 & 6 (Actuator Under Battery)
Option #1—Acid Shield for Under Battery-type Actuator
Cut the center section from an antifreeze plastic jug (6/5” x 10”). This will make two shields with built in bends to go between the fender apron and the O.E.M. Actuator Bracket. The bottom of the jug also makes a nice parts tray.
Option #2—Using O.E.M. Style Clutch Cable Retainer Clip [Fig. 1]
If you would like to use the existing O.E.M. style clutch cable retainer, cut it off the diaphragm about 1/16” from the retainer groove, then file or grind flat and round edges. Install in place of 3/16” washer and hairpin clip.

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