Well,,after much time and money put into changing the OTF dash switch and vacuum switch, encoder motor, vacuum thinggy under battery, 4X4 STILL WAS NOT WORKING,
So lying in bed ..POOF, I had a thought.
What if I removed the encoder motor. Took out the gear that slides onto the transfer case, welded and adapter,(short 3/8 socket extexsion) and weld it on the gear purpendicular to the ground. then I could take a 3/8 stock rod (from the hardware for $3.00) put in a few bends and such, run it just behind my right inside leg, cut it to a short 3 inch length, made a handle and seal with rubber,
I thought.
OK, mental check list,,If I manually shift the lever would that engage the front axles? Well they are activated by the vacuum switch on top of the transfer case. So when it is engaged into 4x4 hi, it would allow the vacuum to let the vacuum thinggy under the battery to engage the front axles.
The only thing that should not work is no lights would come on to let me know if the 4x4 is engaged,,,,,I could live with that.
So the next day I set out to try my idea,,,,,,,

It took about 1 1/2 hours to complete everything.....Oh, I bet you are wondering how I held the gear from the old encoder motor in place so it would not slide off,,,,I took a piece of 1/2 wide 1/4 thick and maybe 6 inches or less in length, I bent it so I could bolt it to the front encoder motor bolt hole and the other end would put slight pressure on the gear to keep it in place.

IT WORKS GREAT, I can still shift on the fly. I dont have to worry if it will stop working or not.:lol2:

Any guestions or If you want pictures let me know.

I want pics!!!

I thinik it's a great idea you came up with, and also a cheap fix...

http://img209.imageshack.us/img209/1787/lastscanwj0.th.jpg (http://img209.imageshack.us/my.php?image=lastscanwj0.jpg)

This is how I did it, try to click on pic to view better.

Brad

Brad, Nice Job, Can I assume that it all works for you OK?

I have been engaging and disengaging it over and over. At a stop,,while going 50 mph down the road. No problems at all.

Brad, Your information should prove to be very helpful to others who may want to choose the same route you took. Especially if they are having Encoder motor, Vacuum or Switch problems on their 4X4's. Glad it worked out for you. Nice Job...


Dino.....

Brad, a few questions. I assume you have the 3 button (2HI,4HI,4LO) 4x4 system. How are you able to apply vacuum to the frt actuator to engage the rt frt wheel or do you engage it manually? Can you shift to 4LO with your setup?

Gonna need a photo pal.

Great question, I have the rocker switch, 2 position, if I want to put into 4 low I will have to lengthen the slot for my shifter to be able to push it further.
I am only using the 2 hi and 4 hi at this time.
To answer you question about how it engages the front axle.
The transfer case on my 1994 jimmy has a vacuum switch located on top of the transfer case. when the lever is switched into 4 hi it automaticly detects it and sends vacuum to the front vacuum thinngy under the battery that engages the front axles.
When I switch it back to 2 hi again it detects this and releases the vacuum and shuts off the front axles.
The good thing about this is that the fron drive shaft also engages and disengages.

I hope this answerd your question.

Brad