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Vacume Disconnect keeps slipping out of gear


 
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OldFart
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Joined: 30 Oct 2007
Location: Florence, Colorado

PostPosted: Fri Nov 02, 2007 4:34 pm    Post subject: Vacume Disconnect keeps slipping out of gear Reply with quote

Hi all...
Here is an interesting one.
Vaccume disconnect front axle... '91 Cherokee, 4.0 L, auto trans, keeps slipping out of 4 wheel drive (disconnecting front end).... so....
I replaced actuator vacume motor with a "cable" controller. Still does the same. Opened it back up to look closer..... gear teeth & splines are fine/sharp.... but.... the splines of the inner axle shaft are NOT extending into the "controller area" very far... the slider gear has very little "spline/meat" to get a grip on ???? Replaced Fork. Fork adjustment allows fork to go all the way to "inside" of adjustment.. just not enough axle spline present/visable ??? Went to salvage yard to look at another one..... opened up actuator...a LOT MORE spline sticking out into the actuator area.
Could someone , in past history, installed a wrong, shorter inner axle ? I checked outer axle tube for damage... all welds look fine and intact. Everything works fine except staying in 4 wheel drive.
Very stumped on this one.
Any ideas ?
Appreciate it.
thanks
Kit (Old Fart)
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OldFart
Member


Joined: 30 Oct 2007
Location: Florence, Colorado

PostPosted: Mon Nov 12, 2007 8:15 pm    Post subject: Vacuum Disconnect issues Reply with quote

Question ?
Does anyone know a source to find the correct length of the axle tubes ?
'91 Cherokee..dana 30.. i believe ? .... vacuum disconnect

I'm wondering... if the vehicle had been in an accident, in the past... which damaged the axle.. breaking welds, etc..... perhaps incorrect repair and welded axle tube to wrong length spec ??
Ideas ?
thanks
Kit (Old Fart)
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djgrayxj
Member


Joined: 26 Sep 2007
Location: Southern California

PostPosted: Tue Nov 13, 2007 4:04 am    Post subject: Reply with quote

Hope This Info Helps
Dimensions

(There may be small differences, dependent upon trim level and/or optional equipment)

Wheelbase = 101.4"
Overall length = 165.3" - 168.8"
Overall width = 67.9" - 70.5"
Track = 58"
Height = 64" (with roof rack 66.8")
Ground clearance from differentials = 7.3" (Upcountry = 8.3")
Approach angle = 37.6* - 38*
Departure angle = 31* - 32.1*
Breakover angle = 21* - 21.9*
Curb weight 2wd = 2,891 lbs - 2,993 lbs
Curb weight 4wd = 3,057 lbs - 3,386 lbs
Cargo capacity = 71.0 cu ft.

Transfer Cases

All the transfer cases used are all chain driven with aluminum housings. T-cases were designated either NP or NV. They are essentially the same t-case...just a different "brand name" (NP was used for the purposes of this list:

NP ="New Process"
NV = "New Venture"

Command-Trac
NP207 - "Command-Trac" part-time only - 2.61:1 ratio low range - used 84-87
NP231 - "Command-Trac" part-time only - 2.72:1 ratio low range - shift pattern 2H - 4H - N - 4L used in 87-01

Axles

Front Axles
84-99 used the Dana 30 high pinion - reverse cut - 27 spline, 1.16" diameter shafts, 7.13" ring gear, (some axles through 91 are vacuum disconnect, 92+ are non-disconnect,
89-95 with ABS have 5-297x u-joints, all 95+ have 5-297x u-joints, all others have 5-260x u-joints)
00-01 used Dana 30 low pinion - standard cut - 27 spline, 1.16" diameter shafts, 7.13" ring gear, 5-297x u-joints

Gearing

3.07 - used with 4.0L engine / manual transmission
3.31 - only available on older (pre87?) 2 door XJs with "Fuel Economy" package
3.55 - used with 4.0L engine / automatic transmission
3.73 - found in some XJs with the towing package
4.10 - used with 2.5L engine usually, and older XJs with the "Off-Highway Vehicle" package.

[/b]
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