4wd - or lack thereof....

[dougg01]

Here is where I am at today in my quest to get 4wd working again:

vacuum switch was replaced and checked...again...

I rerouted vacuum from the ported source using a 'V' with one leg going to climate controls, etc and the other strictly for the front axle stuff.

Yes, the TC motor works. Or else, I wouldn't get vacuum at the actuator.

I have 15-20+ in/Hg at the actuator (replaced because battery acid had deteriorated the diaphram).

What i discovered last night was in my troubleshooting I had removed the cable to ensure it was not bound up too tightly. When I put it back together I must have tightened the nut insert (stop) on the diff end all the way. Cable couldn't hardly move.

I loosened this up last night to the point I could tug on the cable and hear it engage (though didn't test by turning the wheel). I am pretty familiar with the sound.

Still no lockup. The actuator does have vacuum, but it can't seem to pull the cable all the way.

I really don't want to do a posi-lok, but I have ordered a locking cable to do just that. I'd rather avoid it becuase my wife and eventually my son drive it and I don't want them to hassle with things that aren't 'normal'.

Tonight I am going to pull the cable to lock manually and put vise-grips on it and see if I have 4wd.

Is it possible that when I troubleshot all this initially and had everything apart the only real issue was the actuator (and was) and I have somehow thrown the diff cable out of adjustment so it can't lock it in....? It has gone in a couple times, but won't stay.

I'm asking here because I know you guys answer my questions.... Good folks. I'm at wit's end with this thing.

Got another post coming on a intermittent hiccup.

[HenryJ]

I like the stock system for the very reason you mentioned. My wife needs simple. The stock system can and does work. With a little trouble shooting, you should be able to figure out what is wong with yours.

Did you try the cable yet?

Is the transfercase , really, engaging the front drive shaft?

Keep in mind that in 4x4 only one front wheel will be engaged as it is an open carrier.

[dougg01]

Hey. I dumped the vacuum stuff. Made my own Posi-lock using my spare cable and bracket then adding the NAPA locking pull/push cable. Its disconnected because I am re-engineering my fix because I was worried the tie-rod bolt might grab the cable during compression. My redo will eliminate that risk. I mounted the t-handle discretely and it's not a pain to use. I will school my wife in its use for the limited times they do need to run it. If'n I had the energy I 'd go manual on the TC too, but it doesn't really buy me anything right now. When I get the redo done (maybe tonight) I'll take pics and let you all know how it works. I have less than $40 in it and its not some hack job.

[F9K9]

Sounds interesting, Doug. Anxious to see it.