mooktank
Member
- Joined
- November 27, 2007
- Messages
- 44
- Reaction score
- 1
- City, State
- MA
- Year, Model & Trim Level
- 1995 Explorer
Well after my CAD would not work with the vacuum switch due to some combinations of the fact I have a diesel engine and a Jeep NP231 transfer case I locked the CAD permanently.
After driving with it for a while I decided I didn’t like the noise and the added inertial and frictional losses are never good for fuel mileage.
Basically the cable is a generic push-pull cable from any auto parts store. Sleeve OD is about .19″ or so and the inner cable diameter is about .06″. It doesn’t seem to have an inner liner so friction is a bit higher than it ought to be. Here’s my solution:
I took the CAD off and drilled a pilot hole through the casing and shift fork. The hole in the casing was tapped 1/8 NPT to accept a 3/16 compression to 1/8 NPT male adapter. The nut and ferrule had to be drilled slightly to clear the cable OD. I used the compression fitting to fix the cable sleeve to the case. The inner cable is put through the hole in the shift fork, cut to length, then bent upwards. I used a self tapping screw and washer to hold the cable securely to the shift fork. I also drilled a few holes in the vacuum actuator to let air pass through more quickly reducing actuation force.
Reinstall the CAD and mount the cable somewhere convenient and you’re all set. You now have positive confirmation your 4×4 will work (if you have a manual case as well). Once in a while it will not shift because of force on the axle shaft. Rolling slowly in 2 wheel drive will make it a but easier to shift.
Pics (sorry about the blurriness in some of them):
After driving with it for a while I decided I didn’t like the noise and the added inertial and frictional losses are never good for fuel mileage.
Basically the cable is a generic push-pull cable from any auto parts store. Sleeve OD is about .19″ or so and the inner cable diameter is about .06″. It doesn’t seem to have an inner liner so friction is a bit higher than it ought to be. Here’s my solution:
I took the CAD off and drilled a pilot hole through the casing and shift fork. The hole in the casing was tapped 1/8 NPT to accept a 3/16 compression to 1/8 NPT male adapter. The nut and ferrule had to be drilled slightly to clear the cable OD. I used the compression fitting to fix the cable sleeve to the case. The inner cable is put through the hole in the shift fork, cut to length, then bent upwards. I used a self tapping screw and washer to hold the cable securely to the shift fork. I also drilled a few holes in the vacuum actuator to let air pass through more quickly reducing actuation force.
Reinstall the CAD and mount the cable somewhere convenient and you’re all set. You now have positive confirmation your 4×4 will work (if you have a manual case as well). Once in a while it will not shift because of force on the axle shaft. Rolling slowly in 2 wheel drive will make it a but easier to shift.
Pics (sorry about the blurriness in some of them):
