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Old 01-09-2017, 09:20 PM   #1
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Question installed manual axel engage no 2wd?

After several 4wd engage issues and being stuck in the snow with my 1990 YJ I replaced the vacuum motor with a manual cable engagement. Now I have great and reliable 4wd, but my transfer case no longer seems to go into 2wd? The engagement kit also has a switch I wired into the leads for the firewall vacuum switch but I have no 4wd dash light as well.
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Old 01-09-2017, 09:40 PM   #2
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I don't see how the TC won't go into 2X due to installing the manual front axle cable.
Have you tried shifting the TC into neutral and then releasing the clutch with the engine running? If so, what happens.
How about shifting the TC into 2X and backing up?

Did you touch the TC linkage at all while installing the cable?

The wire to the switch on the firewall is hot at all times with the key on. The vacuum grounds the circuit and causes light to light.
I think what should happen is the switch that came with the kit should make ground now. Is there any adjustment to the switch?

Good Luck, L.M.

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HEI distributor with computer and all related relays and wiring removed.
No back seat.
12K Badlands winch with dual batteries.
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Old 01-09-2017, 11:54 PM   #3
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Had me puzzled too. I have gone to neutral and even 4lo but I may not have let out the clutch to turn things over. Didn't mess with the linkage, just pulled off and plugged the vacuum tubing. I can tighten the switch down some more to see if it closes (directions in the kit said not to overtighten) and I'll recheck the firewall ground. If it were easy, it wouldn't be a Jeep! Thanks for the quick response Luckymac!
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Old 01-10-2017, 01:49 AM   #4
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When you state you will recheck the firewall ground, that makes me think that the wires that came with the kit takes power from the wire to the vacuum operated solenoid on the firewall and runs that wire to a switch somewhere that's controlled by the new cable. Then a second wire runs from the switch back to the vacuum solenoid and grounds where the solenoid used to ground. From what I am thinking the vacuum solenoid is no longer necessary and you might have removed it completely.

You may have to back up a few feet in 2H to pop the TC out of 4X. I don't know why I think this, but somewhere in the dark recesses of my poor broken memory I seem to have a shadow of some event or another.

Let us know what works for you. I'm sure that you aren't the first or last person to experience the stuck in 4X issue.

Good Luck, L.M.
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1987 YJ-4.2L-Standard Shift- Re-manufactured Carter Carb-2" body Lift-31X10.5X15 BFG KOs-188K Miles
HEI distributor with computer and all related relays and wiring removed.
No back seat.
12K Badlands winch with dual batteries.
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Old 01-10-2017, 08:48 PM   #5
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I did leave the vacuum switch in place, ran a wire from one side of the axle switch to the firewall screw previously grounding it and a second wire from the axle switch to the vacuum hot lead. Going to lift the wires from the axle switch and meter to see if still open when engaged - then tighten switch 1/2 turn at a time until it meters closed (hopefully it will get there!) As to the T-case, after looking at other posts on linkage issues I'm going to take a look at my linkage, I was pretty "aggressive" rowing the lever during the stuck in the snow issues and I really suspect my linkage has slipped. Thanks again.
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