S-10 Posi-Lok Installation

If your Chevrolet S-10 is a 4x4 vehicle, you may want to install a Posi-Lok system onto your truck. This system replaces your S-10's vacuum-actuator with one that is operated by a cable, allowing you to have more control over your vehicle's wheels and engage them from inside your vehicle with an on-dash control. Although it may seem intimidating, installing Posi-Lok on your S-10 is fairly simple and should only take you a few hours to do.

Instructions

1

Open the hood and disconnect the battery from the vehicle. Remove both terminals with a socket wrench and lift the battery out of the engine compartment.

2

Use a socket wrench to remove the bolts from the lower driver's side kick panel. Remove the bolts from the steering column panel and pull it off the dash.

3

Mark the throttle mounting bracket hole above the two upper triangular mounting bolts on the dash, to the left of the steering wheel.

4

Use a drill to make a 11/16-inch hole in the S-10's firewall. Secure a grommet to the firewall.

5

Install the dash bracket on the right side of the kick panel's u-nut. Use a sheet metal screw and two 3/16-inch flat washers to install the dash bracket. Use the bracket, as a guide, to drill a 3/16-inch hole into the dashboard.

6

Bend the center dash brace 90 degrees and install the kick panel's u-nut. Make sure to align this with the 3/16-inch hole.

7

Remove the screw from the bracket and reattach the steering column cover. Reinstall the screw and tighten it.

8

Pull the cable through the firewall and install the nut, washer and rubber grommet to the firewall. Use a torque wrench to tighten the cable's nut to 10 foot-pounds. Reattach the S-10's kick panel.

9

Place a jack underneath the S-10 and lift it up. Support the S-10's front end with jack stands. Locate the vacuum actuator underneath the vehicle in front of the two front wheels. Twist the cable end spring to free the cable from the S-10's actuator. Remove the cable.

10

Use the socket wrench to remove the steel cable fitting from the housing of the actuator. Remove the wires from the wire clamp.

11

Remove the electrical connector from the switch by pressing in on the two retaining tabs and pulling it off.

12

Remove the three mounting bolts from the housing with the socket wrench. Remove the housing from the differential. This will allow you to access the spring. Twist the spring in order to release it from the differential.

13

Pull the Posi-Lok cable from the firewall. Place the Posi-Lok cable onto the differential and make sure the cable button is fully secured. Align the cable in the differential shaft and engage the retainer spring.

14

Reattach the housing and reinstall the three bolts. Tighten the new cable into the housing. Reattach the S-10's electrical connector .

15

Remove the two jack stands from the truck and lower the S-10. Reinstall the S-10's battery.