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Old 03-20-2013, 09:31 AM   #1
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No 4X4 (need to help where to start! PLEASE!!!)

91 YJ 4.0

I KNOW THIS HAS BEEN ASKED 1000 TIMES...just need a little guidance.

Jeep Newbie, but I've worked with the CAD on my 86 Ramcharger. This is a bit different.

I've read through the stickies and forums, but I am still a bit confused where to start. You guys have been great.

Here's the deal:
1. Driveshaft turns just fine
2. no 4WD indicator light comes on EVER
3. Front axle doesnt engage
4. Shifts fine into 4HI, 4LOW, etc...just no turning from the front axle.

I'm hoping it's something simple before I have to begin replacing major components or permanently lock it in.

I've found several vacuum diagrams, but is the one I attached the best one. I've attached on from a 95, will it be the same for my 91?

What should I do FIRST?

Thank you for your help...

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Old 03-20-2013, 10:25 AM   #2
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You need to locate the vacuum lines on your Jeep. If they are anything like mine they are all dry rotted cracked and broken. 1. You have options you can stay with the factory original vacuum set up and replace all that is wrong at a cost. 2. you can go to the stickies at the top of the page and find threads on how to lock the front end in permamnently cheap by locking the fork over with moving the clips, a spring, washers etc. The front shaft will turn all the time but no issues. 3. You can buy and install a Posi-Lock cable asssy so from in the cab you can engage the front axle at any time.

Choices you need to make. Fixing the old system is just as expensive and labor intensive as the posi-lock. he quick easiest way is to go to the stickies and lock the fork over permanently cheap.

I have a posi-lock installed and no issues cost $150.

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Old 03-20-2013, 10:34 AM   #3
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Originally Posted by jokerchief462 View Post
You need to locate the vacuum lines on your Jeep. If they are anything like mine they are all dry rotted cracked and broken. 1. You have options you can stay with the factory original vacuum set up and replace all that is wrong at a cost. 2. you can go to the stickies at the top of the page and find threads on how to lock the front end in permamnently cheap by locking the fork over with moving the clips, a spring, washers etc. The front shaft will turn all the time but no issues. 3. You can buy and install a Posi-Lock cable asssy so from in the cab you can engage the front axle at any time.

Choices you need to make. Fixing the old system is just as expensive and labor intensive as the posi-lock. he quick easiest way is to go to the stickies and lock the fork over permanently cheap.

I have a posi-lock installed and no issues cost $150.
Who's your posi lock through?? I've got 4x4 no problem but I'm thinking of kinking and hiding my vacuum lines and goin posi lock
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Old 03-20-2013, 11:19 AM   #4
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All the parts sites offer them. I got mine from extreme terrain it was on sale with free shipping.
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Old 03-20-2013, 10:16 PM   #5
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Figured it out....I'm a dumb F!

PO lifted jeep with out extending the vacuum lines from the transfer case, so they were too short and not even connected...ran new lines and 4x4 works great now!

Thanks for the help...
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Old 03-20-2013, 11:11 PM   #6
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Figured it out....I'm a dumb F!

PO lifted jeep with out extending the vacuum lines from the transfer case, so they were too short and not even connected...ran new lines and 4x4 works great now!

Thanks for the help...
Did you extend them or run new all together?
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Old 03-20-2013, 11:21 PM   #7
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Just ran new ones...figured might as well.
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Old 03-20-2013, 11:49 PM   #8
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Just ran new ones...figured might as well.
How did you do it? I would like to keep mine organized. Color coated?
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Old 03-21-2013, 11:18 AM   #9
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Who's your posi lock through?? I've got 4x4 no problem but I'm thinking of kinking and hiding my vacuum lines and goin posi lock

Don't kink them over as they will dry out and fail. This will cause may cause your engine to run bad.

Be sure to either plug the line or better yet buy caps (cheap at your local auto parts store) and cap them where they leave the engine.
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Old 01-03-2014, 05:47 PM   #10
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I don't have any vacuum at the actuator, 2wd or 4wd. I've got vacuum to the TC switch, tested by removing 4 hose clip on top. Removed TC switch and ball(?) seems to move easy enough. Could TC vacuum switch be bad? Or does this seem like bad vacuum lines?
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Old 01-03-2014, 05:59 PM   #11
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I don't have any vacuum at the actuator, 2wd or 4wd. I've got vacuum to the TC switch, tested by removing 4 hose clip on top. Removed TC switch and ball(?) seems to move easy enough. Could TC vacuum switch be bad? Or does this seem like bad vacuum lines?
Could still be both the t-case vac switch is like $9. Pretty easy to change. Then check the two lines that go to the vac motor. If you don't have vac then it's the line from the manifold to the case switch. They are a real pain to track down and they just seem to crack and fall apart as soon as you need the 4x4.
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Old 01-03-2014, 06:11 PM   #12
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I've got vac to the TC switch now. Isn't that coming from the manifold now? I don't have vac to either side of the vac motor.
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Old 01-03-2014, 06:15 PM   #13
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replace the vacuum switch
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Old 01-03-2014, 06:22 PM   #14
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Originally Posted by odellzr View Post
Figured it out....I'm a dumb F!

PO lifted jeep with out extending the vacuum lines from the transfer case, so they were too short and not even connected...ran new lines and 4x4 works great now!

Thanks for the help...
Thats awsome..
He lifted it and turned it into a poser Jeep.
Good catch and enjoy your rig.
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Old 01-03-2014, 07:46 PM   #15
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Nope. That wasn't it. Replaced TC vac switch and still don't have vac on either side of 4x4 actuator at axle, but I still have vac at TC vac switch connection. LPS guy didn't think old TC switch was bad either, since switch button depressed easily enough and reset as it should. So now I'm guessing it's the vac lines?
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Old 01-04-2014, 07:43 AM   #16
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Yeah I had one of my lines crack by the fire wall between the battery and the engine. See if you can follow them from the shift motor back and look for cracks. I had to have some help with mine. Had a buddy with an air gun blow a little air through and we could hear the leak. Make sure to use low psi less than 10.
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Old 01-04-2014, 08:08 AM   #17
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I just lost my 4x4, heard a loud clank from front end and now nuthing up front, still have low and high but front wheels arent turning,--9deg. out right now so will have to check latter what happened...ahhh crap!!!

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