I would love to hear if anybody knows what i can use as a replacement acuator for my 89 dakota w/a 3.9. all parts stores are stumped. the doorman # 600-202 isn't correct. there are no listings Im in a bind. original owner and has 200,000 miles on it, like to keep it going a little longer, please help. dodge sais the part is discontinued.

 

I think a few people had good luck on www.rockauto.com or www.ebay.com. I think someone said the Ram's version works with some modification.


Here are some part numbers from the parts manuals we have in the FAQ.


4338 578 MOTOR, Vacuum Disconnect 87-90

5300 8828 1991-93

Ram
87-88
4137 725

89-93
4506 116

 

well as far as i can tell, if you own a 87-93 dakota and you need that part your s.o.l. because it no longer exist. i had to disassemble the old actuator, removing diaphram and grinding off washers to save the old shaft, took apart a $100.00 brand spankin new actuator so i could steal the diaphram. had to drill and tap old shaft to hold new diaphram on with machine screw and loctite. had to use the old diaphram housing and reassebbled it and works like new, ya just as easy as a sunday morning! I believe the part was a doorman # 600-202 in stock at carquest

 

reading this makes me hope mine isnt bad. before i tore my truck down it was stuck in the lock position and i cleaned it up hoping its just some dirt and grime.

 

if you need full description of how to , just let me know, kind of a pain in the rear, no punn intended, but there is no alternative since there is no replacement part available. the Doorman part # 600-202 is the one i used.. and you have to be carefull taking old one apart , because you need alot of the parts.

 

Just running into this myself... The vacuum unit is definitely bad. The listed replacement holes don't fit the cover. And 4338 578 which mine is, is a Discontinued part. Can't get it aftermarket or from a dealer. Apparently they only made them for 2 years. (Doesn't mean they didn't get used on more than 2 years worth of trucks...)

The guy helping me with this (he talked to the dealer since I am at work) mentioned that we should be able to order one for a 3/4 ton (right size vacuum unit different cover) and finagle it to work. But I would love to hear your method in detail Al...

 

Another possible solution is the 4x4 Posi-Lok, which replaces the vacuum motor with a cable that you can manually actuate in the cab of the truck. It won't be automatic anymore (you'd need to shift the Transfer Case, and then lock up the front axle), but it is all mechanical, so it will always work, and it is also an easy way to get 2WD Low Range, you can shift your transfer case to 4WD LO, but not lock up your front axle.

There is some good and bad news though. While they don't currently have a kit for our trucks, their faq page (http://www.4x4posi-lok.com/faq.html) states that they are working on one. I did e-mail them to inquire about the progress of a kit, but didn't get an answer. I think if everyone here interested started e-mailing them maybe they'll realize there is some demand for it. It would be nice to have options out there, especially since the vacuum motor is discontinued.

 

Honestly - if I could find a 95/96 extended cab that isn't rotted out I would just jump on it. I honestly love the first gen truck - tough solid small trucks. I'm in Michigan - no luck with that though.

 

been a month and no problem yet, still works. Phaidout, i sent you the instructions, its not that bad to do, no choice really, inless you want a 4x2? lol!

 

ok, this reply is for the people that send me pm's and want to know how to fix your actuator motor. you have to bite the bullit and buy the wrong actuator that doesn't fit. part # Doorman 600-202, it's for a later model dakota, it wont fit, but vaccuem diaphram is the correct size. ok now picture taking the old one apart , ya, breaking open the diaphram housing, grinding off old rivit on the end that holds on the washers to the diaphram. throw away the old diaphram and washers, AND ONLY THE DIAPHRAM AND WASHERS! EVERYTHING ELSE WILL NEED TO BE REUSED! Dont break any of the old **** or your DONE! Now take apart that $100.00 doorman 600-202, do the same thing and save the new diaphram and washers and outer diaphram cover, just so when you put it all back together, there is something shiney and new for your $100.00 repair for a .50 cent diaphram. Everything else goes in trash. Ok last but not least you need to take the old rod that you ground off the rivet, file it as flat as possible where you ground rivet, center punch for drilling and tapping. I do not know what size drill , tap, or screw I used , sorry this info was forgotten, so you have to go to an ace hardware , first look for a stainless machine screw that will fit in washers, loose is better in case you drill crooked, or off center. find the corrisponding drill and tap and go to town on the shaft. make sure you go in enough so you dont bottom out your screw, and when assembling and use red threadlock, just put it back together recrimp the vaccuem actuator together and mine has been working since i did it back in January. So,to sumarise this whole process, all your doing is paying $100.00 for a stupid diaphram and putting it in your old unit. it's not hard , but dont mess up or your out $100.00, LOL. Best of luck and happy 4 wheelin!