Jeep YJ plastic 4x4 lines where?? - Jeep Wrangler Forum
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Old 04-14-2014, 11:09 AM   #1
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Jeep YJ plastic 4x4 lines where??

Jeep 4x4 - Wrangler Forum Gallery

1990 YJ 2.5 5speed.

Trying to work out where the plastic lines go... Not sure what the previous owner did under there???

I have a crude jpg of whats under my hood for the plastic lines for the 4x4 actuator above.. Could use some help as my service manual does not show the colors. I have some questions.

1 the red line from the intake is connected to the blue line going to the transfer case is this correct? This is how it is now.

2 the black line from the actuator is connected to nothing where does it go?

3 the yellow line from the actuator is split at the actuator one side goes straight to the transfer case the other split goes to a box on the firewall with a couple of wires.

4 the green line from the actuator goes straight to the transfer case

These plastic lines appear to be damaged in one spot and have hose splices in them.

Any help would be appreciated cause Im lost...

Thanks don

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Old 04-14-2014, 11:14 AM   #2
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The black line should T into the yellow line. The thing on the firewall is the 4x4 indicator switch that turns on the 4x4 light on the dash.

All four of those lines will also make their way over to driver's side of the transfer case.

Personally, I replaced all of it with a Posi-loc.

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Old 04-14-2014, 11:32 AM   #3
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I may have to change to whole plastic harness... because I have 3 lines on the actuator and 3 lines from the transfer case. I guess I will crawl under it and see if theres 4... I was hoping to piece the lines back together because they were just damaged in one spot.

Thanks

So the black line T's to the box on the firewall?
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Old 04-14-2014, 01:19 PM   #4
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I used this diagram when I was trying to figure it out
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Old 04-14-2014, 03:07 PM   #5
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That diagram is so awesome... thanks so much... my blue or purple line which is hooked up to the engine vacuum which is WRONG... DOH DOH DOH... I think my red line is broken under before the transfer case... I have to get under the Jeep and see...Its pouring rain today....

Thank You SO much....
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Old 04-14-2014, 04:00 PM   #6
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This might help:

Amazon.com: Jeep NP231 Transfer Case Vacuum Switch Wiring Harness and NP207: Automotive



Although locking over the CAD selector is probably better than spending $50 on it...
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Old 04-14-2014, 04:28 PM   #7
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Thanks... I may have to purchase the harness.. Thanks for the Link.
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Old 04-15-2014, 02:37 AM   #8
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My plastic had cracked in a few places, so I just replaced the cracks with some rubber hoses and RTV sealer.

Works great! This may be cheaper route if all your lines are there, just damaged.
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Old 04-15-2014, 12:29 PM   #9
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I purchased the wrong size vacuum line online the other day 50 ft and its just the right size to fix my broken lines... Thanks thats probally what Im gonna do I have yet to take it off road yet.... Cant wait to get all the bugs fixed first!
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Old 04-18-2014, 02:44 PM   #10
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Quote:
Originally Posted by klx677 View Post
I used this diagram when I was trying to figure it out

Replace the damaged lines... went and tested it in 4x4high by going in a circle and the jeep jumped squalled while in a turn... So YEAH 4x4 now works.

Thanks Again for the info.

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