Join Date: Sep 1999
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Re: Front Axle disconnect
OK, have you checked that vacuum is actually getting to the shift motor on the axle? With the engine idling, shift the case into 4wd. Crawl under the Jeep and check the line that faces the passenger side tire to see if vacuum is there. Then shift it back into 2wd and check the lines on the top of the shift motor. One of them should have vacuum now (the one that doesn't is for the 4wd dash light). If you have vacuum in each of the lines, then either your collar is stuck on the axle splines or the diaphram of the shift motor is defective. Remove the shift motor from the axle tube by loosening the four bolts. Be ready to catch some fluid but it won't be much. After you remove the motor, try to slide the collar back and forth by hand. If it is stuck, some gentile taps with a hammer and long screwdriver should free it. Then slather a good amount of axle grease on the splines, working the collar back ad forth by hand to work the grease under the collar.
If the collar is free and you had vacuum at each motor ports, first the 4wd and then the 2wd, the problem is the motor diaphram itself. You can buy one from a Jeep dealer or junk yard.
When you put the motor back on the axle, make sure that the fork goes into the center groove of the collar. You can buy a gasket from the Jeep dealer if you like or use some RTV to make a gasket. Good Luck!![img]/wwwthreads_images/icons/smile.gif[/img]