2nd Gen Non-Engine/Transmission 4x4 won't work :(

[OaborbaG]

well i finally got my truck back after..... 2 months from transmission being replaced for the 2nd time, but. . . anyways my 4x4 would work when i took it in, and it doesn't work now, i htought it was the sensor problem like it was dirty, i cleaned it out, now my 4x4 light is on, it wasn't before, and when i put it in 4x4 lo or high, hte transfer case switched, but the front axle won't lock, before it would do the same thing only the light wouldn't come on, now its on all the time, the hose that goes right by the sensor looks like it has a cut on the bottom of it, right before it goes into the axle, what is that for? and could it be a cause of it, any help would be greatful the only place around here i could think of taking it to would be the dealer, and id on't wanna do that thanks again





Aaron

 

[vssman]

The front axle motor works on vacuum. There is a switch on the top of the transfer case that switches the vacuum from one side of the motor to the other. A good vacuum hand pump will help you test the system.

 

[Sticks]

Ditto above. If the lines are reversed, or damages (small cut?) then it will not work. Make sure the lines are connected on top of the transmission/transfer case as well. It will be a square rubber plug with four lines.

 

[Joe G.]

The square rubber plug can be forced on wrong so you want to check that.

 

[OaborbaG]

i've checked the vacuum lines on the transfer case traced them back and they are correct, i'll check the ones on the front drive line, see if i can switch them or something, but the light doesn't come on anymore even when its in 4wd so i'm not sure whats going on, i wanted to go to the track this wed, but if i cant use 4wd i doubt i'll make it so... hopefully i can fix it soon

 

[wcjp]

The rubber boot may be plugged in correctly but still leak. I had the exact same problem with my 96' after new clutch. I had always had a small vacuum leak. The boot is not available by itself from DC. I took new vacuum line from the Tcase to a 1/4" plastic vacuum extension. Then plug the 1/4" extension directly into the rubber boot. This will make a tight fit with a good vacuum seal. It's possible to remove the boot altogether. I didn't to maintain the factory index. I'll be able to figure it all out in a few years since I didn't write it down. I also used small zip ties at every vacuum connection.

 

[vssman]

Any oil drawn into the vacuum lines from the pump will cause them to swell and not seal properly. I like the zip tie fix, I'll have to try that.

 

[Willie G]

I installed a "4x4 Posi-Lok" from Tellico 4x4. It is a cable that has a pushbutton on a push/pull knob on the end. It mounts to the dashboard and goes through the firewall. The other end of the cable connects to the axle disconnect. The purpose is to do away with the trouble prone and expensive vacuum actuator.



WillieG

 

[vssman]

How do you like the posi-lok? Can you leave the front axle locked and turn the transfer case on & off as needed (i. e. snowy days when you only need 4X4 to go up a hill)? Any noises or banging when engaging into 4X4?

 

[OaborbaG]

4wd still isn't working, what are the green and greay lines that kinda run up over the transmission and up again'st the firewall they have no ends on them and aren't connected to anything. . breather lines maybe? i'm gonna just go buy new vacuum line run new lines and if the 4wd still doesn't work, what could it be? thanks





EDIT: when you turn the key to on isn't the 4wd light supposed to come on?? well mine doesn't come on at all, and i don't think their is a fuse since its run off of vacuum

 

[DLBurns]

Per the drawing supplied me with my 2 wheel low kit... the Green line is a vent and the gray line is the vacuum in.

Hope this helps

 

[OaborbaG]

yea i just figured that out haha saw where the gray one plugs in so i plugged it in and instantly had 4wd again already did some nice psi launched felt good Oo.

 

[Sticks]

Originally posted by OaborbaG

i've checked the vacuum lines on the transfer case traced them back and they are correct, i'll check the ones on the front drive line, see if i can switch them or something, but the light doesn't come on anymore even when its in 4wd so i'm not sure whats going on, i wanted to go to the track this wed, but if i cant use 4wd i doubt i'll make it so... hopefully i can fix it soon

You were supposed to do that a month and change ago!



Glad you found your problem and got it working.

 

[OaborbaG]

yea i procrastinated a little bit i finally did it only because i'm doing a pull this saturday and i kind of need 4wd lol glad i figured it out though, my ac doesn't only come out through the top vents now too