To all you XJ’s out there struggling with stupid vacuum 4x4 actuators.
Here is a fix that I learned by tearing into it today that costs zero dollars and I thought that posting it here might be of use to some of you.

The actuator is a dog style clutch that moves a sleeve over the two parts of the axle locking it up (passenger side axle is broke in half and the sleeve slides over the break when 4x4 is engaged). Well after tearing into mine today I found that there are two retainer clips that hold the fork to the motor piston (piston connected to air diaphragm). Well it just happens that if you remove the furthest from the diaphragm retaining clip and then slide the fork to engaged position without moving the piston, it is a perfect fit to reinsert the retaining clip, locking the piston up solid without any jerry rigging. What do you know, you now have 4x4 24/7- always on (not the t-case of course, just the axle). Put it back together and replace any axle grease you lost and never wonder if you’re in again. Jacking up the passenger side minimizes lost grease.


NOTE: This fix permanently locks the front axle up, so if you are looking to still be able to switch in and out buy the cable solution.

 

no cable. i popped those c clips like pop corn. if ur going to wheel get a long shaft out of a newer cherokee w/o cad and swap at the trail

 

Lost 4x4 today in a foot of snow on my way to some friends to go jeep sledding...just wanted you to know this was probably one of the easiest fixes I've had to do to a major component to a vehicle

 

hahahah i freaking hate the vacuum fork no wonder it was only on there for a year or two. My for was loos so i just swapped it out and have 4 wheel drive again pretty simple really

 

now could i find another axle shaft at the junk yard and replace the stock axle with it??