The 4wd stopped working on my 90 Cherokee (231 TCase). I came across some folks recommending a bypass as described in this thread:
https://www.cherokeeforum.com/f51/fr...ss-91-a-38629/

So I decided to try that. However, rather than pull the C clip and move the fork over, I simply turned the housing around upside down and the fork met the locking ring in the locked position perfectly. I plan to leave the vacuum lines disconnected. I gave it a quick try in the gravel and sure enough the 4WD works as it should.

The one difference I notice is that the 4WD handle is much harder to engage and disengage. Is that normal after this procedure? Can the we still shift on the fly like we used to or is it better to stop first?

Anybody have any experience with that?

 

You can still shift on the fly at any reasonable speed.

Not sure why it'd be more difficult.

 

Has anybody else simply turned that cover/fork over so that it lines up with the locked position? Could that potentially cause a problem?

 

switch on transfer case maybe sticking causing whole issue ?

 

Do you mean the vacuum switch? I guess that's possible.

Another quirky thing: the 4WD lights have never been on since I've had the Jeep (about a month). Whether it's in 4WD or not - no lights indicating either position.

 

Just as a follow-up: I've taken approximately 8-10 miles of trails since this modification and the 4WD is shifting in and out flawlessly and with normal tension on the shift lever. So far this seems to be an excellent solution to the vacuum axle dilemma. Not sure why there was initial tension on the lever - that is gone now.

 

Maybe you just needed to use it...

Ever read this?

Here's how the factory suggests you shift the transfer case and I've been doing this since these things were new and I worked at the dealership. Quoted from the owner's manual.

"To engage, shift the transfer case lever from 2H to 4H while the vehicle is moving at any legal speed". I let off the gas, throw the lever and then tap the gas and let off.

4L position: " To engage, slow the vehicle to 2-3 MPH , shift the transmission to Neutral, then shift the transfer lever to the right and pull firmly rearward to 4L".

 

you don't have to flip it over, inside the the cover by the fork there is an e- clip, just remove it and slide the fork over and re-install the e-clip.

 

That's the way I've always done them.

 

Thats the way most do it, and the OP stated he was aware and even linked the thread in the write ups.