Be careful when building a home brew posi lock. My first attempt was using a brake cable for a bicycle and hand throttle switch for a lawn mower. I tried this set up based on a story I'd read on a Jeep forum site. Needless to say that cable and switch was WAAAAY too weak and it failed miserably the first time I attempted to use. I came up with my current set up based on the same idea just with beefier parts. It works like a champ. Pics coming soon.

Found this online a few years back.

http://www.geocities.com/tonysmudbog/Posi_Lock.doc

As the post above me says, I'd upgrade to large components.



The axles from non disco housings WILL work. You simply need make a cover for the CAd hosuing, and get an inner axle seal and install it inside the housing near the carrier.

The non CAd housings seal on the otherside of the cad unit instead.

yeah well the guy before bought a choke cable from lordco and had it hooked up bought god was it garbage. Ive just taken it out after trying to make it work twice. anyone know where i can find one of these write ups?

can you show me how?

How do I get to those pics?is a great unit but like so many other after market items available for the XJ I decided I could build something for cheapert than what was available. I built a home brew posi lock for my XJ whan my vacuum junker died. I used a hand throttle cable available at you friendly local Napa auto parts store and made my own. I already know what you guys are going to say PICTURES!!!! OK, I'll post some pics of my personal posi lock set up when I get home in a couple days. I built my posi lock for about $40 dollars in pieces parts and a couple hours of my personal time. $37 dollars of it is for the hand throttle. The most expensive piece of the puzzle. I have had my personal posi lock for about 2 years now with ZERO problems. engages and disengages every time and works like a champ. My 4x4 light even lights when it is engaged. Santa Claus is bringing me diff lockers front and rear for Christmas. it will be interesting to see if that brings any new challenges.[/quote]

I also have a 91 2 door. and i am using the posi lock. my vacuum system wouldnt work, but the actuator is still good. the cable is a very easy install, and works really good. i thought more of us had these due to the actuator going out. the kit should only cost around 200. i got mine from my local 4 wheel parts store.

I bought my jeep and it already had a possi lock cable in it but im have trouble locking in it work somtimes when i keep messing with it but most of the time it will not lock and when i do it slip out after a min or two so wat do i do?

I had one in my old 87. Nothing but trouble that thing was a major POS. Mine was a hassle I got stuck numerous times because of that thing. Sometimes I would have to get rolling a little to get it to engage. It came with the truck so I never checked to see if it could be adjusted.

Here you go everybody...

http://www.jeepforum.com/forum/f12/h...ite-up-595515/

i've heard of people flippin the accuator over so it holds the collar engaged all the time. any adverse affects from doing this?

I just opened it up and moved the collar over put a hose clamp next to it moved the fork over to line up with the collar, and wala I now have 4x4. and have had no problems.

I have heard of people running this way for years, but I only did it because I could not afford the posi-loc. so if you are on a tight budget like me, I would go with the $2.00 hose clamp. But if you can afford it go for the posi-loc.

good luck either way.