Posi-lok engagement problems - JeepForum.com

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post #1 of 27 Old 12-22-2008, 03:15 PM Thread Starter
flame0086
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Posi-lok engagement problems

So I got the retail posi-lok last christmas and this is the first time I got to really test it out. My problem is that it only engages at the very end of the cable pull. When I drive around, it likes to slip out, you can hear it click out and when you pull it, you can her it rubbing against the splines as it tries to engage. I usually have to pull the cable while I'm driving to make sure it sticks in 4wd.

I went under the jeep and adjusted the cable going into the collar housing. Now the cable is barely in the housing, like if I unscrew it one more turn it comes undone from the housing. Screwing the cable into the housing is going the wrong way and it will never engage.

I'm not sure what to do. As far as I know, this is the only way to adjust the cable. If anyone had a similar issue or knows what to do, please let me know. Thanks in advancement.


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post #2 of 27 Old 12-22-2008, 03:31 PM
Richmond88yj
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I feel your pain bruthah! <insert cool bromance pic here>

I've done the posi lock thing, both home brew and retail. All have let me down at the worst possible time.

My remedy (getting to it) is a balanced driveshaft and a TJ shaft in the front right.
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post #3 of 27 Old 12-22-2008, 03:37 PM
YJames90
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Make sure theres no slack in the cable so that the complete cable housing is secured to the Jeep.
Is the shift fork on the slide shaft located inbetween the 2 correct E clips? If its over too far that could cause your problem

Quote:
Originally Posted by Poke View Post
Spring Over is not for you.... yet





My 2.5 to 4.3 swap thread
http://www.jeepforum.com/forum/f12/4...begun-1237704/
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post #4 of 27 Old 12-22-2008, 03:45 PM Thread Starter
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Quote:
Originally Posted by Richmond88yj View Post
I feel your pain bruthah! <insert cool bromance pic here>

I've done the posi lock thing, both home brew and retail. All have let me down at the worst possible time.

My remedy (getting to it) is a balanced driveshaft and a TJ shaft in the front right.
One of these days. For now on a college budget and working with what I've got.

Quote:
Originally Posted by jamesx2 View Post
Make sure theres no slack in the cable so that the complete cable housing is secured to the Jeep.
Is the shift fork on the slide shaft located inbetween the 2 correct E clips? If its over too far that could cause your problem
That fork should be in there correctly, I checked so many times over the past year. I'm not sure what you mean about the cable slack. The cable is screwed into the housing securely, its been screwed into the housing further but then the cable pull will never reach the engage position.

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post #5 of 27 Old 12-22-2008, 03:46 PM
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It sounds to me like the shifter cable isn't adjusted properly or the fork is in backwards & if it's just barely catching before disengaging, I'd want to make sure the internal assembly was correct before looking elsewhere. If you have your installation instructions, you can look at the last page at figure 14 to see how everything fits together. If you don't have the instructions, you could easily have downloaded these by going to the 4x4 Posi-lok site. The cable adjustment shown in figure 14, arrow A, can be used to adjust the exact positioning of the shift fork.
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post #6 of 27 Old 12-22-2008, 03:55 PM Thread Starter
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Quote:
Originally Posted by Alfons View Post
It sounds to me like the shifter cable isn't adjusted properly or the fork is in backwards & if it's just barely catching before disengaging, I'd want to make sure the internal assembly was correct before looking elsewhere. If you have your installation instructions, you can look at the last page at figure 14 to see how everything fits together. If you don't have the instructions, you could easily have downloaded these by going to the 4x4 Posi-lok site. The cable adjustment shown in figure 14, arrow A, can be used to adjust the exact positioning of the shift fork.
14A is what I've been adjusting. I'm like 99% sure that the fork is in there properly. I guess I'll open it up one more time, but I'll probably do that later in the day. Thanks for the help so far.

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post #7 of 27 Old 12-22-2008, 04:12 PM
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I am starting to be glad that I did not invest in a posi-lock. You could just slide the fork over and fix it there. I pulled the bolt in the cover plate on the axle then slid the fork over and put a longer bolt in to hold it. Mine has been like this for thousands of miles and lots of serious wheeling. 4WD always works and didn't cost anything.

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post #8 of 27 Old 12-22-2008, 04:40 PM Thread Starter
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Quote:
Originally Posted by Jeeeeeeeeeeeeep View Post
I am starting to be glad that I did not invest in a posi-lock. You could just slide the fork over and fix it there. I pulled the bolt in the cover plate on the axle then slid the fork over and put a longer bolt in to hold it. Mine has been like this for thousands of miles and lots of serious wheeling. 4WD always works and didn't cost anything.
I tried something simillar in the past, but the fork kept on wanting to spring back to the disengaged position. I couldn't figure out how to hold it in place. No one ever mentioned that bolt idea, the only thing I got was it would hold it self in place

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post #9 of 27 Old 12-22-2008, 05:54 PM
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Quote:
Originally Posted by Jeeeeeeeeeeeeep View Post
I am starting to be glad that I did not invest in a posi-lock. You could just slide the fork over and fix it there. I pulled the bolt in the cover plate on the axle then slid the fork over and put a longer bolt in to hold it. Mine has been like this for thousands of miles and lots of serious wheeling. 4WD always works and didn't cost anything.
I put an Aussie in my D30. I'm stuck using the disco (vacuum actuated or otherwise) until I can afford Warn hubs.

I'm probably going to do the home-brew NAPA cable over Christmas break (it's nice working at a college) as my vacuum motor has been getting slower and slower...

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post #10 of 27 Old 12-22-2008, 06:09 PM
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did you replace the fork when you installed the posi? sounds to me like it's worn out where it rides on the the cable and is allowing for too much play. mine's been in service for 5 years and the only problem i've ever had was a worn out shift fork. never had to adjust the cable since install and this is the second jeep i've had it in

also, the nature of the lock is that you need to be rolling just a hair to get it to engage all the way. it's very rare to get the splines lined up just so on the first try so you need that motion to line things up while you pull the lever.

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post #11 of 27 Old 12-22-2008, 06:25 PM
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With the housing off did you try to slide the collar back and forth over the splines just to make sure it moves freely?
Are the E-clips on corrctly and in the notches?
Is the fork faceing the correct way?
Is the fork inbetween the correct e clips. It dosent sound like it is being you have to loosen the jamb nut so far back.

Quote:
Originally Posted by Poke View Post
Spring Over is not for you.... yet





My 2.5 to 4.3 swap thread
http://www.jeepforum.com/forum/f12/4...begun-1237704/
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post #12 of 27 Old 12-22-2008, 06:33 PM
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Heres something from one of my old threads
"The end of the cable that screws into the housing was in too tight so the cable couldnt pull all the way to the left to slide the coupler onto the shaft. I backed out the screw while the houseing was off so I could see the fork slideing all the way to the left. Re-installed , jacked up the front pass side and had my son manually spin the tire as I engaged the posi-lok. It works perfect now except the 4wd light stays on now full time. no big deal . I will just remove the wire fron the indicator"

Quote:
Originally Posted by Poke View Post
Spring Over is not for you.... yet





My 2.5 to 4.3 swap thread
http://www.jeepforum.com/forum/f12/4...begun-1237704/
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post #13 of 27 Old 12-22-2008, 06:41 PM
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In this picture there are two e-clips together.
I Think I removed the one closest to the jamb nut screw so the cable can slide out further. Its not much more movement but just enough to make it work.
I think haveing two clips there is just a safeguard so the cable dosent fall out

Quote:
Originally Posted by Poke View Post
Spring Over is not for you.... yet





My 2.5 to 4.3 swap thread
http://www.jeepforum.com/forum/f12/4...begun-1237704/
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post #14 of 27 Old 12-22-2008, 07:25 PM
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I think that you've got to troubleshoot this until you figure it out. Mine works fine and has more than enough thread adjustment to allow me to set the control knob where I'm confident that it's fully engaged and fully disengaged. It's solid and reliable so far. As previously mentioned, when engaging I let the rig roll slightly to help align the splines. I figure that it's similar to the vacuum motor putting a constant push on the fork while the rig starts rolling.
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post #15 of 27 Old 12-23-2008, 07:20 AM
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The shaft should have 3 grooves in it - ONE clip goes into each groove. I believe there's one groove on each side of the shifter & this may be what you're missing - the shifter isn't locked into place on the shaft/cable assembly so it doesn't move all the way into place.

If you continue to have problems, you should take some pictures with the whole unit dis-assembled showing the shaft, clips, housing, and shift fork & someone here can tell you exactly how this should go together. You can also have a close look at the 4x4Posi-Lok Site and use one of their Customer Support options like "Phone", "Ask a Question", or "Instant Answer". This is a simple unit and shouldn't be difficult to assemble into a working configuration if you look at it logically.
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