When it rains it pours!! I was having CAD problems and in the process of trying to fix it, my t-case went to **** or something. I replaced the vacuum switch and found out that it isnt being actuated. Upon reasearch thanks to zman17 and others I think that the "shifting sector" is the part that actuates the switch. If the shifting sector was broke or slipping or something to that effect, the t-case wouldnt engage. So, my next question is, can an improperly adjusted shift linkage cause this? How do you adjust it properly? I think I am going to use a depth gauge on my fancy new starett digital calipers to check and see if the sector is coming up high enough to engage the switch. If the T-case is broke I am selling it, I will spend twice what I paid for it just to get it in good running condition where everything works and Im not wondering when its gonna leave me in the middle of a field miles away from people and no cell service.

 

http://www.crownautomotive.net/categ...e.html#4638844
heres a diagram

 

If its an internal transfer case problem, don't fix it. Get a posilok, or, grab a locking throttle cable from Napa, and make your own version. There are various DIY's out there on the web.

 

Ok I see your point, but I wonder. If the shift sector is broke or something else internal, what is everything else in there looking like? Is something laying in the bottom of my t-case waiting to get wrapped in the chain and wreaking havoc?

 

Anything is possible. If you have a place to work on it, dropping the case, pulling it apart, and having a look really isn't that bad of a job. (not like the old NP203/205 cases, that were cast iron, and weighed a ton......)

 

Right I may just do that. I have a 205 laying around here somewhere they are heavy. I think im gonna make a posi-lock and roll with it. If it dies I guess ill just go for a junkyard t-case or rebuild the one in it providing the case doesn't bust.

 

The t-cases in the half ton trucks are pretty famous for losing the rear output shaft snap ring, and that WILL cause the case to do really rude, and expensive... things. Something to pay close attention to when you have the opportunity.

 

Haha will do. I found a good article on making a poi-lock. They did it similarly to the way I thought of doing it. They took all the guesswork out of it though.

 

Link?

 

Here ya go:
http://www.jeepforum.com/forum/f12/home-made-posi-lock-write-up-595515/