4WD weird problem - JeepForum.com
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post #1 of 4 Old 01-21-2014, 12:29 PM Thread Starter
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1992 YJ Wrangler 
Join Date: Jan 2014
Location: Northampton
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4WD weird problem

Hey guys new to the forum. Great site. I havent seen this discussed yet. I have a 1992 Jeep wrangler that i just acquired by trading my civic (best move I ever did) Its a 2.5 with a 5speed manual transmission. Has 157,000 miles with a rebuilt transmission. The problem I'm having is engaging 4wd. I had it at Midas and they diagonosed it with a bad 4wd actuator. A brand new one was installed and they said it worked and engaged fine. I live in pa and were getting 6-10 inches of snow took it out today to try out my "working" 4wd to find out it doesnt work at all. 4wd light comes on. But it doesnt engage. When it's in 4wd setting it sounds like something is rubbing or grinding or rattling. It's hard to describe. I need the 4wd for work. Midas is now closed due to the storm. I'm also a volunteer firefighter so 4wd is absolutely essential...any guidance would be greatly appreciated. Stuff I've tried. putting the transfer case in neutral works as well as 4lo i feel the gear change but the front wheels NEVER engage. hope you guys could help me out. Thank you!

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post #2 of 4 Old 01-21-2014, 12:41 PM
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1990 YJ Wrangler 
Join Date: Jun 2007
Location: San Diego
Posts: 18,556
The front axle is engaged by vacuum powered motor on the passenger side of the axle housing. They generally work ok but can stick, the hoses fall off or crack and rarely the vacuum switch on the transfer case goes bad. You can add a cable control, commonly called a posi-lock. Or, fix what you have. Or, put in TJ shafts and eliminate the disconnect. Or take off the vacuum motor, slid the fork over and lock in in place with some washers.

They are many threads on this you can find.

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post #3 of 4 Old 01-21-2014, 12:43 PM
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1993 ZJ 
Join Date: Apr 2009
Location: Michigan
Posts: 1,540
Sounds like did Midas two things wrong. First they didn't put the shift fork back in it's proper location so it's not fully engaging the collar the way it should, and they obviously did not do a proper check to make sure the problem was fixed. Check the shift fork on the front axle, pull the housing off and make sure it's actually moving the way it should. Have someone help you with that.
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post #4 of 4 Old 01-21-2014, 12:55 PM
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1995 YJ Wrangler 
Join Date: Jan 2013
Location: Atlanta
Posts: 350
^^^ this. get ur hands dirty, it is a simple job.

..And you got ripped off @ midas
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