4WD Actuator Repair on a Maine Tundra after 10 Winters with Photos

Friends,

Unlike the older threads that show a pristine actuator heres some real world examples. Despite my best efforts this is usually what you end up with in Maine. I have spent endless hours banging, heating, freezing and cursing during various repair events.

In the photos, the screws with raised heads are good to go. It's the other screws that are worn down from corrosion that my smallest bit will not bite into because there is nothing there.The screws on the other side are the same, so I have a least two if not three to remove.

Setting up the clock settings is not my question since there is already plenty of vids out there. I looking for suggestions on how to remove these screws while saving the plastic. Now, I do have an actuator coming Friday but my goal is to return it for my $500 refund.

Thanks in advance for any helpful suggestions.

 

Not sure if you could try cutting a slit in the head of the screw with a dremel/cut off wheel and then use a flat head screwdriver to remove it?

 

That's on the list. But for the screws against the Tcase, that's probably not an option.
Thanks!

 

Superzilla bro soak them in it they will come off.