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Old 04-04-2019, 02:26 PM
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4WD shifting question, and some fun repairs

Quick question: What in the transfer case would keep vacuum to the Center Axle Disconnect always shifting into 4WD, regardless of the lever position? I have checked the vacuum actuator on the CAD, very strong vacuum; however, vacuum is always to the left or drivers side hose, regardless of where the transfer case is.

Now on to the fun repairs. 6 separate things wrong with 4WD on this Jeep so far. Started today to fix the 4WD light in the dash. Opened up the dash. No bulb. Usually not a big deal, I've got a bunch of those 194 bulbs. Previous owner tossed the bulb holder too. Ugh. Bought 5 for $6 on Amazon.

Still no light. Check the switch. Broken wire. You can get that switch at NAPA, P/N NOE 6002937 for $40 ($27 plus shipping). But it'd take a week.

IMG_1639 by michael delage, on Flickr


Instead, I disassembled the Weatherpak plug, spliced in a new wire, with some marine grade heat shrink.

IMG_1641 by michael delage, on Flickr

Still no joy. Vacuum actuator had a nipple broken off.

IMG_1644 by michael delage, on Flickr

Cleaned that up, tapped the case, and made a new nipple with threads.

IMG_1648 by michael delage, on Flickr

Assembled with a bit of Rectorseal, and it works.

IMG_1651 by michael delage, on Flickr

Unfortunately, all that was for nothing, as the damned thing won't shift! Any ideas?

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Old 04-04-2019, 02:31 PM   #2
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I switched mine from vacuum to a cable. Then I wired in a new switch from the old fuse box and had it so when the cable is in the locked position the switch is activated, turning on the light on the dash. Then I caped all the vac lines because honestly it's a lot of trouble than it's worth.

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Old 04-04-2019, 02:52 PM   #3
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4WD shifting question, and some fun repairs

There are a few mods to keep the 2 shafts together which should get you in 4wd, not sure about your light? Mine isn’t working either, don’t care though. Under the tech forum, under 4wd disconnect sticky


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Old 04-04-2019, 03:00 PM
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Originally Posted by steves92 View Post
There are a few mods to keep the 2 shafts together which should get you in 4wd
Thank you for the reply. The shafts are engaged; actually, that's the problem! I can't get them to disengage.

No matter what I do with the 4WD selector in the cab, the vacuum never switches to the right (passenger) side of the Vacuum Actuator.

If I pull the hoses off and use the wrong hose, I can disengage the CAD, and the light goes out.

Something in the Transfer Case must not be functioning to switch vacuum to the other hose...

Filled out signature so people know what vehicle we're talking about here.

Michael
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Old 04-04-2019, 03:18 PM   #5
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Old 04-04-2019, 03:24 PM   #6
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I started with this. https://www.quadratec.com/products/5...gaAgihEALw_wcB

Then I attached a magnetic switch near the handle so it turns on the light. So much more reliable than vacuum.

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Old 04-04-2019, 04:51 PM   #7
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Is the light that important??? You should know when you're in 4WD just by looking at the shifter.

By the time you get done messing around with trying to fix what you have, you could have the cable operated lock in and working flawlessly, likely spending less money and a lot less hassle. You would also gain 2 Lo by shifting into 4Lo and not engaging the lock.


Someone may have done a mod to the axle already instead of messing around trying to diagnose and attempting to source parts to fix a very common problem.
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Old 04-04-2019, 04:53 PM   #8
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Originally Posted by mudbug85603 View Post
Is the light that important???


You should know when you're in 4WD just by looking at the shifter. By the time you get done messing around with trying to fix what you have, you could have the cable operated lock in and working flawlessly, likely spending less money and a lot less hassle. You would also gain 2 Lo by shifting into 4Lo and not engaging the lock.
Personally I like the light

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Old 04-04-2019, 06:35 PM
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Originally Posted by mudbug85603 View Post
Is the light that important??? You should know when you're in 4WD just by looking at the shifter.
Negative, Ghostrider. I can move the shifter all I want, the CAD is staying engaged. It's not right, and it's not just the light that's the problem here.

Bang that lever all you want, but the light tells you what is actually going on. The light tells you if the CAD locked the axles or not. Unless the wire is broken...


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Originally Posted by eddieboy1233 View Post
Personally I like the light

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Agreed!
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Old 04-04-2019, 06:39 PM   #10
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Negative, Ghostrider. I can move the shifter all I want, the CAD is staying engaged. It's not right, and it's not just the light that's the problem here.



Bang that lever all you want, but the light tells you what is actually going on. The light tells you if the CAD locked the axles or not. Unless the wire is broken...









Agreed!
Are you saying the fork is engaged and it's still not locked?

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Old 04-04-2019, 06:44 PM
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Originally Posted by IRQ View Post
Thank you. MudMagnetYJ's first post in that thread confirms what I've already come to suspect, there is a vacuum switch on the Transfer Case that isn't functioning. "Check Transfer Case Vacuum Switch. Replace or Repair if Switch is Difficult to Move or Binds."

Here's his Service Manual scan, if I remember my vBulletin coding correctly:

Quote:
Originally Posted by MudMagnetYJ's Post In That Other Thread View Post


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Old 04-04-2019, 06:48 PM
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Are you saying the fork is engaged and it's still not locked?

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No, not at all. I'm saying that no matter what I do with the shifter, the Transfer Case is sending a vacuum signal to lock the CAD. The axles are definitely locked together.

Everything moves smoothly. I can engage and disengage the CAD with just a piece of hose and a quick suck!

It's just that the Transfer Case is always sending a 4WD vacuum signal, even when it shouldn't...
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Old 04-04-2019, 06:54 PM
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trying to fix what you have, you could have the cable operated lock in and working flawlessly, likely spending less money
I see your point, but no money has been spent thus far; the Cable Locker you mention is I think around $200.

I suspect this is going to be a free fix; I might have 2 hours into it so far, separate from typing here...
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Old 04-04-2019, 06:58 PM   #14
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No, not at all. I'm saying that no matter what I do with the shifter, the Transfer Case is sending a vacuum signal to lock the CAD. The axles are definitely locked together.



Everything moves smoothly. I can engage and disengage the CAD with just a piece of hose and a quick suck!



It's just that the Transfer Case is always sending a 4WD vacuum signal, even when it shouldn't...
My honest suggestion is to just switch to a cable system. Best thing I ever did. I tried dealing with vacuum but first the disconnect itself started acting up the the switch in the TC went bad. That's a huuugeeee pain to mess with.

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Old 04-04-2019, 06:58 PM   #15
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It sounds like you have it figured out.
Install a new vacuum switch and that should cure your non-disengage issue.

Let us know what happens.

Good Luck, L.M.
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Old 04-04-2019, 06:59 PM   #16
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My honest suggestion is to just switch to a cable system. Best thing I ever did. I tried dealing with vacuum but first the disconnect itself started acting up the the switch in the TC went bad. That's a huuugeeee pain to mess with.

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I just saw where you said you wanted to make it free. I would just lock it in place so it's always engaged. For a while I drilled and tapped a bolt into the housing to he the fork over. You really don't need them do disconnect.

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Old 04-04-2019, 08:30 PM   #17
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Sorry I didn't see this sooner....

Yes as you've figured out there is a vacuum switch on top of the t case that you need to replace...
Typically the mode of failure is moisture getting into the t case from deep water play and then steaming and condensing inside.... you get a little rust inside the switch and presto perma lock front axle....

If you haven't changed ur t case fluid lately, grab 2 quarts of dexron when you get the switch.
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