Does anyone know what the part number (from any manufacturer, any dealer/parts store) is for the Vacuum Shift Actuator (CAD) vacuum harness? I will be trying to reclamp the ends on the CAD and see if that helps - but I'm not confident.

I was getting a 'clinking' in the front end when engaging 4wd... I originally thought it was the U-Joints, but after grenading half of the front end, and learning how the 4WD actually worked, I decided it was the shift collar not fully engaging due to crap vacuum.

Removed the CAD and verified there was a leak in the actuator itself. Fully rebuilt (read: built) a new CAD and installed it - still having the problem, and while the CAD definitely needed to be replaced anyway, I think the vacuum harness is junk. As said before, it could just need to be clamped on (the clamps literally disintegrated when removing the harness) and it fits pretty loosely - so I can't imagine it hold vacuum pretty well in any sense.

I can't find the part anywhere - alldata, rockauto don't list it at all. Hoping someone else has replaced this and kept record!

This thing was CRUUUUUSTYYYY! While pulling it off, the crappy aluminum mounting holes nearly all snapped. I was going to reuse the housing, but couldn't remove the main E-Clip holding the actuator in, so figured I may as well spend the 17$ and buy a new housing too - had to use a prybar and BFH to snap the housing in half, to get the fork out... but it all worked out well.

 

Some folks have just used some vacuum line to replace the harness.

The steel lines like to rot out too, and leak. You can replace them with rubber as well, or, just bend up some brake line of the appropriate caliber.

The harness on mine is 'clamped' with zip strips. Not pretty, but, it works, and they won't rust.

 

Jesus christ, zipties. DUH. Here I am thinking I gotta find some spring clamps, or megasupersmall wormgear clamps.... I can just ziptie it in 2.5 seconds and be done! Good on you!

I haven't looked too much into the vacuum harness itself - didn't know there were steel lines involved. I'll get up under there this weekend and see what the deal is.. might just run 2 new rubber vac lines and be done with it. I assume (they look) about 1/8"?

 

Steel lines run from just below the t-case, along the cross member, and then down the frame. Changes to the soft lines just behind the axle. Not sure on the size..... Should be able to hand-bend them without trouble. (and it's like 3 bucks for 6 feet of line... which I think should be enough.)

Mine collected some moisture, which subsequently froze.... and 4x4 stopped working... Thawed them out, blew 'em out with air, and that seems to have solved it.

 

Great - thanks! I've got a lot of crap to do this weekend me thinks!

 

Well, back for my yearly bitch about the 4wd system that stiiiilll doesn't work.

I replaced the steel lines, as well as the soft lines to the actuator itself, and still, nothing. All that's left, really, is the harness from the transfer case to the steel lines (which are now just soft lines). Does anyone have a diagram, or advice on where the actual harness plugs into the transfer case? I'm hoping I don't have to drop it at all to get to it.

I'm referring to this harness, that needs to be replaced (i figure). I'm just going to build my own, because I don't really feel like waiting, or paying, for this one.

http://puredieselpower.com/dodge-pro...m-harness.html

 

There is a switch on the t-case, right by the shift arm.

 

Thanks - And that's where the 4 port vac harness plugs into?

 

Yep.

 

UPDATE:

Removed 3/4 of the harness. Went looking for the grey/green vac hoses in the engine compartment. Searching, searching, searching, find the port on the manifold that it should be connected to. There was a vac hose connected to it, but only one... the cruise control. I wasn't aware the hvac controls, cruise, and 4x4 all ran off the same manifold port.

To make a long story short, the HVAC controls also haven't worked since day one. Replaced the controls... no dice... turns out someone took the Y connector off the manifold, hid it behind the engine, and plugged the cruise line into the mani. Why, I have no idea. A mistake? Maybe. In any case, I connected everything they way it should have been.. andddddd.... BAM! HVAC controls work! I put the 4wd harness back in place, hooked it all back up... andddddddd.... BAM! 4x4 works! -- I did find that the rear u-joint on the front driveshaft is destroyed. Mega binding on hard turns in 4wd only, wicked metallic clunking... not good. So, the driveshaft is half out, going to remove it today, replace the U-Joints, and hopefully.. I have a working 4wd system, that is relatively noiseless.

Thanks for all your help so far!