This is for the replacement of the vacuum controlled 4WD actuator in the front axle of my '89 YJ. It really was an extremely simple swap that took less than 1.5 hours. I purchased the motor from Advance Auto for $82 after they matched an internet price. The box contained the following:
1 shift motor
4 bolts and lock washers
1 large and small e-clip
1 o-ring
1 cover gasket
Instructions:
1. Jack and support vehicle if you feel necessary and place something to catch oil under the motor cover(I used a towel)
2. Remove 3 vacuum lines going into shift motor
3. Remove 4 bolts in each corner of the cover and pull cover off; it may take some prying and pounding
This step frightened me as 3 of the 4 heads snapped right off leaving the rest of the bolt. I sprayed the remains with an rust loosener and let them sit for 20min while I worked on replacing the shift motor in the cover. I then took vise grips, clampped them on as much of the bolt remains as possible and they came right out. I think the corrosion in the cover is what did them in, I was able to remove by hand after the first turn.
4. Once the cover is off you need first mark the fork location in reference to the housing and then remove 2 e-clips holding the motor shaft in place. One is on the shaft and the other larger one is against the cover holding the motor in there tight. This was a pain to get on and off and took the longest. I ended up just breaking it since a replacement was included.
5. Place the new o-ring the the new motor and slide it through the housing and into place. I put a drop of oil on the o-ring to slide it into place easier. The shift fork must be in place for the shaft to slide through.
6. Put the new large e-clip on first, this too was tough. I used channel locks to force it down into place. It is a very tight fit and may take some time to get in place. Next replace the e-clip on the shaft to hold the fork in place; this one was much easier.
7. Sandwich the new gasket between the axle and motor housing and tighten in place with 4 bolt and lock washers.
8. Hook it up and you're ready to go.
I do have some pictures I'll post up later, but it really was very simple and nothing was hard to find. Hope this helps someone in the future.
1 shift motor
4 bolts and lock washers
1 large and small e-clip
1 o-ring
1 cover gasket
Instructions:
1. Jack and support vehicle if you feel necessary and place something to catch oil under the motor cover(I used a towel)
2. Remove 3 vacuum lines going into shift motor
3. Remove 4 bolts in each corner of the cover and pull cover off; it may take some prying and pounding
This step frightened me as 3 of the 4 heads snapped right off leaving the rest of the bolt. I sprayed the remains with an rust loosener and let them sit for 20min while I worked on replacing the shift motor in the cover. I then took vise grips, clampped them on as much of the bolt remains as possible and they came right out. I think the corrosion in the cover is what did them in, I was able to remove by hand after the first turn.
4. Once the cover is off you need first mark the fork location in reference to the housing and then remove 2 e-clips holding the motor shaft in place. One is on the shaft and the other larger one is against the cover holding the motor in there tight. This was a pain to get on and off and took the longest. I ended up just breaking it since a replacement was included.
5. Place the new o-ring the the new motor and slide it through the housing and into place. I put a drop of oil on the o-ring to slide it into place easier. The shift fork must be in place for the shaft to slide through.
6. Put the new large e-clip on first, this too was tough. I used channel locks to force it down into place. It is a very tight fit and may take some time to get in place. Next replace the e-clip on the shaft to hold the fork in place; this one was much easier.
7. Sandwich the new gasket between the axle and motor housing and tighten in place with 4 bolt and lock washers.
8. Hook it up and you're ready to go.
I do have some pictures I'll post up later, but it really was very simple and nothing was hard to find. Hope this helps someone in the future.
