Join Date: Nov 2000
Location: Dale City, VA
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Re: axle disconect on YJ Dana 30
Well, what would you know... I'm new to jeeping myself but this was one of the first thing we had to fix on my buddys rig. Basically, you have vacuum routed from the manifold to the vacuum switch on the top part of the transfer case. From here it goes to the vacuum shift motor on the front axle. Testing is easy. Pull the two vac connections off the vac motor, start engine in neutral (chuck wheels), plug the vac connectors one-by-one with your finger, in 2H you should feel the vac on one tube, then in 4h it should switch to the other. If ther is no vac then the hose is hosed (leak) somewhere, if there is vac but it doesn't switch then it's the vacuum switch on the tcase, if there is vac and it switches then it's the vac shift motor. Vacuum switch is a $20 part and easily replaced (it just screws right out, we needed a pipe wrench though). Motor is maybe $40, vac harness same. Let me know if you need more help.
'91 YJ, I-6, 3" lift, 31s