[Flattop]

I recently purchased a 95 wrangler with 2.5 and a 5 speed. I noticed that the 4X4 indicator was not coming on when putting it in 4 wheel dr. I researched the site for info and found out about the vacum lines from the intake to the fromt axle. I started to trace these lines and found that both lines were dried out and broken in half. Now my question is what is the easiest way to replace these lines? does any one have a schematic drawing of the lines and where they connect? I found both lines coming off of the intake and followed them across the firewall to where they seemed to join however, one of the lines had what appeared to be a vent on the end of it and it just stopped. is this correct? Any help will be greatly appreciated. Thanks

[sentinal02]

Originally Posted by Flattop

I recently purchased a 95 wrangler with 2.5 and a 5 speed. I noticed that the 4X4 indicator was not coming on when putting it in 4 wheel dr. I researched the site for info and found out about the vacum lines from the intake to the fromt axle. I started to trace these lines and found that both lines were dried out and broken in half. Now my question is what is the easiest way to replace these lines? does any one have a schematic drawing of the lines and where they connect? I found both lines coming off of the intake and followed them across the firewall to where they seemed to join however, one of the lines had what appeared to be a vent on the end of it and it just stopped. is this correct? Any help will be greatly appreciated. Thanks

stupid imagestation. this is the diagram that should be in the FAQ along with my write up of the disco's problems:



and yes, one of the lines is a vent that terminates in a check valve. should be the blue line. easiest way to fix it is with some new vac tubing, match your colors at both ends and then swap them out one at a time so you don't get them mixed up. if you want to get really thorough, get some colored zip ties, the small ones, and at each end of the tubes put the same color tie to mark which is which. i do this all the time when i'm removing wires or hoses and it works great later on when you have 4 or 5 identical hoses and you can't remember which one goes where.

[MLJeeper]

edit beat me to it

[Flattop]

Thanks for the help, do I just get bulk vacum tubing in that diameter? If the Vacum lines don't get it then the next step is the switch on the axle right?

[sentinal02]

Originally Posted by Flattop

Thanks for the help, do I just get bulk vacum tubing in that diameter? If the Vacum lines don't get it then the next step is the switch on the axle right?

that's what i would do. either that or go for the posilok solution and be done with the vac setup. before you go tearing into the electrical system, make sure your shift motor is pulling in and that you're actually in 4wd. obviously you're not at this point with the broken lines, but if new lines don't fix the problem it could be the motor itself is worn out and not pulling the fork over far enough to engage.

[EABiker]

If you want a "quick fix", without replacing all the lines, you can use heat shrink tubing to splice the old lines together. Find some that is just larger in diameter than your hard lines, and extend the shrink tubing several inches on either side of the break. I also like to put a second layer right over the break to stiffen things up. I've been doing this for years to fix those pesky, brittle hard lines they use for emissions equipment.

EA