4wd light on in 2wd, 4wd won't engage, transfer case low range works... - Jeep Wrangler Forum
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Old 08-16-2009, 07:23 PM   #1
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4wd light on in 2wd, 4wd won't engage, transfer case low range works...

Just wanted to check if you guys think this is all caused by that whole vacuum system. If so, what are the options as far as repairing it, options to change it out to something that eliminates the vacuum, etc.

The transfer case gears seem to be working as far as high and low range. I pull it back to 4low and I get serious granny gears. But no 4wd light. Neutral does disengage the trans output. 4hi and 2wd seem to feel the same.

The 4wd light is on with the transfer case lever in 2wd. It goes off when the transfer case is shifted to anything other than 2wd.

Thanks guys!

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Old 08-16-2009, 08:25 PM   #2
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http://www.wranglerforum.com/f8/how-...ems-17802.html

check it out.
swap in a posi lock and dump the vacuum actuator. Or swap in a TJ hp dana 30 with the same gears.

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Old 08-16-2009, 08:41 PM   #3
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sounds like maybe your vaccum lines could be reversed, maybe at the motor on the front axle. also ask ccain for a picture of his $2.00 fix. i installed it in my 94 and it works great.
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Old 08-17-2009, 03:12 PM   #4
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what i did. ccain's fix.
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JUST PEE ON IT AND WALK AWAY.
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Old 08-18-2009, 11:26 AM   #5
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ok so apparently my motor is different from all of the others I've seen. My vacuum lines are side by side and the hoses are connected together in a little housing. I did flip the connector 180 out so the lines were reversed. Now my dash light works correctly in relation to the position of the transfer case shifter. however, still no engaging of the front axle. Guessing I'll put the thing up on jackstands and engage 4wd, then put it in first gear. I'm HOPING I at LEAST see the front driveshaft turning from the transfer case.
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Old 08-18-2009, 11:58 AM   #6
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hey there. mine is the same as yours.
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TREAT EVERY STRESSFUL SITUATION AS A DOG WOULD.
IF YOU CAN'T EAT IT OR PLAY WITH IT,
JUST PEE ON IT AND WALK AWAY.
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Old 08-19-2009, 01:58 PM   #7
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Hey! It WORKS! No Money, just some cleaning, etc. I played with the transfer case and checked the front driveshaft, it was locking the driveshaft so I went ahead and pulled the shift motor out. I bench tested it with the handheld vacuum pump and it was moving the fork and holding pressure. So I put it back together. Noticed the two lines in the connector that plug to the vacuum tubes were a little worn, so I wrapped a small section of electrical tape around each tube, then connected it all back up. Road tested it and now everything is working as it's supposed to. WooWoo!

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2000 TJ 4.0, Auto, Green w/black hard top
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