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Old 04-24-2013, 09:44 AM   #1
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yj transfer case switch trouble

The front differential suddenly quit locking in, I have vaccum going to the transfer case switch but not going through it to the differential when I engage the transfer case. I tried two new vaccum switches and still no vaccum to the differential! I can jump vaccum across the rubber plug at the transfer case and the differential will lock! what is going on here?

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Old 04-24-2013, 10:00 AM   #2
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What's going on is inevitable failure of a poorly conceived and designed system.

You can permanently lock the shift collar in place on the front axle...

You can install a PosiLok cable and manually actuate the shift collar on the front axle...

Or you can fiddle with the vacuum crap and guarantee yourself another failure down the road, or even worse... Deep into the woods.

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Old 04-24-2013, 10:49 AM   #3
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Try adjusting the linkage. The stick moves the linkage and inside the case the parts move to cntact the ball on the switch to make it activate. That may be the issue not enough throw.
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Old 04-24-2013, 11:49 AM   #4
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Quote:
Originally Posted by evan7024 View Post
The front differential suddenly quit locking in, I have vaccum going to the transfer case switch but not going through it to the differential when I engage the transfer case. I tried two new vaccum switches and still no vaccum to the differential! I can jump vaccum across the rubber plug at the transfer case and the differential will lock! what is going on here?
Evan,

It seems like your front axle disconnect is going bad. This is a common problem with the D30 in the YJ's. Luckly, there are a number of products out there to fix the issue.

Crown Automotive makes 2 different options to lock the collar. First, you can permanently lock it with their Posi-lock Permanent Lock Kit. This will make your front axle live all the time, so all you have to shift is the t-case.

They also make a Selectable Posi-Lock Kit. The kit eliminates the vacuum disconnect and changes it to a cable actuated system. Both kits are easy to install and should only take you around an hour or so.

Let me know if you have any questions about either kit. I'll be happy to help!

-Zach
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Old 04-25-2013, 09:51 AM   #5
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Evan,

It seems like your front axle disconnect is going bad. This is a common problem with the D30 in the YJ's. Luckly, there are a number of products out there to fix the issue.

Crown Automotive makes 2 different options to lock the collar. First, you can permanently lock it with their Posi-lock Permanent Lock Kit. This will make your front axle live all the time, so all you have to shift is the t-case.

They also make a Selectable Posi-Lock Kit. The kit eliminates the vacuum disconnect and changes it to a cable actuated system. Both kits are easy to install and should only take you around an hour or so.

Let me know if you have any questions about either kit. I'll be happy to help!

-Zach
Your website says the selectable PosiLok kit is out of stock.
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Old 04-26-2013, 10:19 AM   #6
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re:

Tried to adjust the linkage, no dice! There is vaccum to the transfer case switch but it wont go through it to the differential, I am thinking about taking a ford egr solenoid and hooking it to a toggle switch to apply vaccum to the front differential. It sounds like it should work and if it does its a cheap fix,I just don't like the idea of spending 200.00 on a posi lock setup or locking the differential full time.
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Old 04-26-2013, 10:29 AM   #7
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Quote:
Originally Posted by evan7024 View Post
Tried to adjust the linkage, no dice! There is vaccum to the transfer case switch but it wont go through it to the differential, I am thinking about taking a ford egr solenoid and hooking it to a toggle switch to apply vaccum to the front differential. It sounds like it should work and if it does its a cheap fix,I just don't like the idea of spending 200.00 on a posi lock setup or locking the differential full time.
You aren't locking the differential full time.... Unless you have a locker installed. TJs have a one piece right side. The vacuum was just a YJ thing, and like I said before, it was ill conceived.

If you don't have a locker installed, you'll be fine with the CAD engaged full time. The posilok cable is really handy, though.
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Old 05-05-2013, 10:40 PM   #8
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I have the same problem. I don't mind going posi lock or rigging it to work but I would like to try and fix it first. I've tried a handful of things. I've changed the vacuum actuator, I've changed the transfer case switch. I've removed all the vacuum lines and checked for cracks and leaks. I've used a air compressor to test the lines to see if it engages. Everything seems to work. I noticed I still had no vacuum to the actuator. Was wondering in it could be the engine not producing enough vacuum to engage the actuator? Probably just a leak I over looked. I've read a lot about how to rig it or add another part. I would really like to learn how to fix it first. Wondering if there is something I'm missing.

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