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Home made Posi-lock

6K views 23 replies 15 participants last post by  jeeplover27 
#1 ·
#2 ·
All I've got left to do is make a handle for the cable and I'll have all the peices I need.
Going to weld up a handle tommorow at work time permiting. Mine does differ a bit from that write up, but not much. As far as wuality goes, I'm going to have to wait and see, but in all honesty, it can't be worse than dealing with the vac system that I keep having problems with.
 
#4 ·
#5 ·
I'm interested to see how this works out for you guys. I bought one of the kits and it is really heavy duty. After shifting it in and out a few times I'm not sure that a bike cable is going to hold up
 
#7 ·
(just in case you missed it) The Toyota E-brake handle was perfect for mine. When you pull it out, it ratchets and locks in the out position (4WD engaged). then to disengage, you just twist the handle and push back in. Mine cost 15 bucks from a junk yard and it is much more sturdy than the el cheapo handles that I found in auto parts stores.
 
#8 ·
How long did this take for you to make? I'm looking at having to do mine soon.
 
#9 ·
I made mine before winter using the locking choke cable from napa, the cable is plenty srong.all the other parts stores had cheap cables and handles. I have used it all winter in wisconsin so it gets quite a bit of use. Reliablity is awesome. when I first installed it I didnt attach the cable well enough to the shoft fork and it pulled out one icy evening. I went home and reattached the cable through the shift fork more securely and havent had a problem since.
 
#10 · (Edited)
mstutzman said:
I made mine before winter using the locking choke cable from napa, the cable is plenty srong.all the other parts stores had cheap cables and handles. I have used it all winter in wisconsin so it gets quite a bit of use. Reliablity is awesome. when I first installed it I didnt attach the cable well enough to the shoft fork and it pulled out one icy evening. I went home and reattached the cable through the shift fork more securely and havent had a problem since.
How long of a choke cable did you buy. and how did you attach it to the Shift fork
 
#12 ·
I'm thinking I might have mine adjusted wrong. I have to really give it a pull and often times slowly go forward before it will pull all the way out and engage.

Is this how yours are working too?
 
#13 ·
Mine took a few evenings after work to from start to finish. I had a lot of trial and error that made it take a little longer. What took the longest was the mods I had to make to the handle I used so that it would fit where I wanted it.

As far as attaching the cable to the shift fork...

You need to buy a cable stop at the hardware store. They slide onto the end of the cable and crimp on the end so that it doesn't slide through the hole. Buy a few of them because you may need to make some cable adjustments to fine tune.

1. drill a hole into the inboard side of the shift motor cover.

2. drill a hole into the center of the shift fork. (Just big enough for the cable to thread through.)

3. thread the cable through the motor cover, then through the spring, then through the fork and crimp a cable stop to the end of the cable so that it can't slide back through.

Check out this link...it gives pretty good pics and descriptions...
http://home.earthlink.net/~stevenschreiber/cabledis.htm

keep us posted on progress...
 
#16 ·
The one thing that the store bought posi lok has that a home brew doesn't is a new cover plate. I considered buying it for that reason, since my stock vacuum motor didn't fair as well as most everything else in ohio winters since '91. I ended up just cutting the rotten vacuum pot off and shortening the shaft so I could seal it all back up.
 
#17 ·
Now I understand the point of this mod, and how to do it, and how it works. But why is it called a posi lock? I understood that posi lock was when bot rear (or front) wheels spin together? Is this because you can engage the stock 4wd lever, and then disconnect the front axels and the truck still thinks its in 4wd and both rear wheels spin? Sorry for the ignorance, and thanks in advance for you answers.
 
#18 ·
You're thinking of positrack, which is a limited slip differential. Posi Lok because you are positive its locked when you pull the handle? No idea really, but it seems to fit ok.
 
#19 ·
YJBlues said:
You're thinking of positrack, which is a limited slip differential. Posi Lok because you are positive its locked when you pull the handle? No idea really, but it seems to fit ok.
Actually, I'm pretty sure that's what it means.

If you want to see a kit for the front axle posi-lock, Quadratec part number 52435.00 or 52435.01 for lifted wranglers.

As you can see, these cause $200 each. But, they also recommend to replace the shift fork with a cast iron shift fork (was 52430.02, but I can't find a link now)...but I don't know if it's really necessary. You guys re-using your aluminum shift fork, have you had any issues?
 
#21 ·
did it on my 87 using the lawnmower throttle/bike cable. lawnmower throttle is right under heater controls. did it in about 45 minutes, even after i broke the upper right bolt off the housing. Use lots of RTV to seal the vac motor and where you run the bike cable through the adjuster nut. engagment is smooth and reliable. tellico tested.



scott
87 yj 258, ba 5/10, 207, 30, 35
 
#23 ·
I got my brake cable the other day and the ends do not come off to thread the cable through the fork. Am I missing something or did I get the wrong cable. If so, where do I need to get the right cable?
 
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