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Old 06-13-2011, 04:31 PM   #1
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1995 YJ 4 Wheel Drive help!!

I have a 1995 Wrangler and it shifts into 4hi but the dash light doesnt come on and only the rear wheels spin. I know it has an open diff whick means only one front and one rear should spin but the fronts dont engage at all. I think the front 4 wheel drive actuator is bad. I have pics and will a new one fix this issue? Thanks for any help.
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Old 06-13-2011, 04:52 PM   #2
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go to 4wd and order the posi lock get rid of the vac system its around $200 but is well worth the money. The yj cad system is so unreliable and is always broken. I got one and my 4 wheel drive always works and i never have to worry about replacing the posi lock.

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Old 06-14-2011, 07:52 AM   #3
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If you are planning on keeping the vacuum system you should check the transfer case switch first. That switch changes which line to the shift motor gets vacuum. It's a lot cheaper than the 4wd motor and if it's bad changing the shift motor won't do anything.

One of the two vacuum lines to the shift motor should have vacuum. When you shift into 4wd the line with vacuum to move to the other one if the transfer case switch is working.
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Old 06-18-2011, 10:37 PM   #4
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When I tested mine before I bought the posi lock, I only had suction on one side. So for a quick fix I just flipped the lines around on the shift motor and my 4 wheel drive worked.
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Old 06-18-2011, 10:57 PM   #5
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Kill the CAD and get 1 piece shafts you'll never have the issue ever again
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Old 06-18-2011, 10:59 PM   #6
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good advice irongrave. i went tj shafts and no problems now.
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Old 06-20-2011, 12:30 AM   #7
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That 4WD actuator need to be replaced. No doubt about that. It looks like it is going to be a tough one to get off of the bracket that holds it in place. Get some PB blaster or rust remover/bolt remover and soak it for at least 1 full day. There are a lot of posts on testing and replacing the 4WD actuator. Once you have properly replaced it you will know what to do next.
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Old 06-20-2011, 12:32 AM   #8
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I have posted this a few times but this one's for you. Good luck. Do this first.
Quick and easy test:
1) Jack up the front passanger wheel so that it spins freely in 2WD.
2) Put the Jeep in Neutral and engage the emergency break.
3) Start the jeep.
4) Crawl under the Jeep and look at the front axle. There is a small disk shapped metal object with two vacuum lines and a few wires connect to it. This is the 4WD actuator.
5) Disconnect the vacuum line closest to the passenger side wheel. Check to see if there is a vacuum to it by holding your thumb over the end of the hose.
6) Reconnect the hose you just checked.
7) Disconnect the vacuum line closest to the drivers side.
8) Check it for vacuum the same way.
9) Now get back in the jeep and put the jeep in 4WD High (one shift down).
10) Perform the same vaccum check on both lines. The vacuum should have switched from one side to the other.
11) If a vacuum is detected and it chages when you shift into 4WD then this tells you that the vacuum is working and your shift problem is probably with the 4WD actuator or the fork.
12) Reconnect the vacuum lines and check to see if the front tire spins freely. If it spins and also spins the drive shaft going back to the transfer case then your 4WD is working. If it spins freely and the drive shaft does not spin then your 4WD actuator needs to be replaced.

If this is the case replace the 4WD acctuator. There are several great descriptions in this link as to how to do this. It is easy and the part only costs about $90 from Autozone.
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Old 06-20-2011, 03:53 PM   #9
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I replaced the actuator and it was a pain in the ass!! But now i only have vaccum coming from the line farthest from the tire. I switched the lines around and the 4wd light comes on when im in 2hi then when i put it in 4hi the light goes off.. I dont know what to do next. Also when i put it in 4wd my front drive shaft spins but its not engaging??
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Old 06-20-2011, 05:30 PM   #10
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Well, with the actuator ruled out, and the fact that you're getting vacuum to at least one of the lines, that leaves two possibilities. One is a broken/leaking vacuum line from the vacuum switch on the transfer case. And the second is that the vacuum switch is bad.
You should have vacuum to the pass. side of the actuator in 2wd and to the drivers side in 4wd.
You're going to have to check the lines that go from the actuator to the switch for breaks and leaks.
If everything checks out with the lines, you'll need a new vacuum switch.
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Old 06-21-2011, 08:32 AM   #11
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Replace the hose that is not getting any vacuum from the actuator to the transfer case. If that does not work change the vacuum switch. From the look of the actuator that hose is probably pretty deteriorated.
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Old 06-21-2011, 10:05 AM   #12
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That and it may have sucked up a bunch of rust and junk from that rotted out actuator.

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