Try replacing the vacuum switch on top of the TC first.

 

Thanks guys, I have been toying with the idea of replacing the switch even though it seems to function correctly but its less than $20 so Im gonna give that a shot first. If not I'll just have to pawn my shotgun and buy a posilock kit. I have to have 4wd.

 

Ok, I changed the t-case vacuum switch. I had to use 4wd before I replaced it so I pulled the outboard hose like normal. I was driving down the road at 20 or so and the 4wd light went out. I couldn't get it to go back in so I replaced the switch and in 2wdthe outboard port pulls 15 as well as in 4wd. I guess the switch isn't being actuated now? Please help me im an ASE tech working on a farm because there are no jobs right now. I need my truck to be working. I can't afford a new tcase so it may be time for new wheels.

 

someone was asking for a temporary permanent lock the other day and zman came up with the idea of a split rubber hose with some hose clamps to lock the collar in the engaged position. i'd either just do that, or cobble up something like the perma-lock part number 1100

http://www.4x4posi-lok.com/app_dodge.html






if you do spring for the posilok, you and 5 other people can still get it here for $163 with free shipping and no tax.
http://www.amazon.com/4x4-Posi-Lok-P...0448623&sr=8-1


if they sell out, here it is for $165
http://www.shopjeepparts.com/posilok...02-p-9493.html

 

Both lines pull 15 at the same time? Or does the vac change when in or out of 4wd or 2wd?

 

It doesn't change always pulls 15 on outboard. New switch.

 

I can't have full time my front driveshaft already needs to be rebuilt. My mpgs kill me already I couldn't imagine all time 4wd.

 

it wouldn't be full time 4wd. it would be full time axle lock, which would turn your front drive shaft, but it would free wheel within the t-case.

most 4wd chevy trucks in the 70's, 80's were setup like this. it might cost you 1 mpg in drag because it turns the front diff.

 

Ok. I wonder though, if the part in the t-case that activates the switch is broke, is something else really f****d up in there?

 

You are right, the internal part that activates and deactivates the switch is faulty.