So did my upper and lower ball joints today, they were all toast , uppers fell appart before i could get the press near them lol. however i ran into a problem on the passenger side axle. My 91 has the disco axle, and when i removed my axle from the housing it came out just fine, when i went to slip it back in, it felt very tight but went in. Installed my wheel bearing and went to turn the wheel bearing and noticed it was very tight to turn, i checked for a grease nipple on lower bj for dragging, but it had lots of room for the u joint to spin by, also i noticed my front driveshaft was turning while rotating this tire. so i thought i might have bumped that little collar inside the disco over while i was re installing the shaft. so i get the truck back on the ground, and go out into the back yard and shift into 4x4, as i am driving it feels locked in, shift it back into 2wd and only back tires spin. so i am assuming the front disco also was disconnected.. I jack the front up and spin the front passenger tire, and it was still turning the front driveshaft.
so my question is how does this vacum disconnect work. i see a couple vacume lines running off the vacume pot on the actuator. when the truck is in 2wd is there constant vacume applied to one side of the pot? and when the t-case is engaged to 4x4 does vacume switch to other side and hold that fork constantly?

this is my dd, no lift, no mods, all stock. . i just want this to work as it should. i read some writeups on how to bypass the disco with moving a c-clip over, or attaching a pto cable to it, not really interested in throwing some tie wire and duct tape on it lol.

anyhelp would be much appreciated!

 

pretty much that how it works vacuum is supplied to a switch on tc case when shifting it vacuum is sent thru app line to either lock or un lock axle

 

There's nothing at all wrong with eliminating the CAD.
A real nice write-up is available here on CF.

 

so locking that axle in ,using that writeup ,wont affect street drivability?

 

As long as driveshafts in good shape. It makes everthing turn at all times up to transfercase.

 

It's the way Jeep built them from 91 on. You'll be fine.