Homemade Posi Lock
#1
Senior Member
Thread Starter
Join Date: Oct 2010
Location: Pagosa Springs, Colorado
Posts: 562
Likes: 0
Received 0 Likes
on
0 Posts
Year: 88-ish
Model: Cherokee
Engine: 4.0 I6
Homemade Posi Lock
Here is the write up for my posi lock. This is a litte lengthy. Sorry.
Things you need.
PTO Cable link
1/4 Inch Compression Union link
5/8 Compression Spring link
Gasket Maker link
To open up the vacuum side use a flat head screw driver and work your way around the seam prying it open. Once it is open all the way you can pull the entire thing apart and cut the diaphragm so that it doesnt seal anymore.
This is the one part that i dont really have photos for. Being that my hands were covered with oil and my camera cost more then my jeep did i decided that it was a better idea not to touch it. You need a pair of needle nose pliers here and you need to pull the holding clips from both sides of fork so that the fork can slide out. Once these clips are out you will see the small ring where they hold in place. This is were i only used one of the clips instead of two. While the fork is out drill a 5/16 hole in it so that it will line up with the hole in the case when everything is back in place. When your putting everything back together put the fork back in place and slide the rod back through til you can see the very first clip ring. Put the clip back in place between so that the clip is between the fork and the wall of the case (vacuum side. Also PM me if this doesn't make sense). Now the fork Is held in place but there is a gap between the cable side of the case and the fork. This is where you slide your spring into place so that it is always trying to push the fork out of 4x4. When the cable is pulled it will lock the axel and as soon as you unlock the PTO cable it will slide out of place again.
So there is the basic write-up. Leave me comments if you have any ways to make this better or easier. So far it works quite well(takes a little longer to put in 4x4 but i know its not going to go out)
Things you need.
PTO Cable link
1/4 Inch Compression Union link
5/8 Compression Spring link
Gasket Maker link
To open up the vacuum side use a flat head screw driver and work your way around the seam prying it open. Once it is open all the way you can pull the entire thing apart and cut the diaphragm so that it doesnt seal anymore.
This is the one part that i dont really have photos for. Being that my hands were covered with oil and my camera cost more then my jeep did i decided that it was a better idea not to touch it. You need a pair of needle nose pliers here and you need to pull the holding clips from both sides of fork so that the fork can slide out. Once these clips are out you will see the small ring where they hold in place. This is were i only used one of the clips instead of two. While the fork is out drill a 5/16 hole in it so that it will line up with the hole in the case when everything is back in place. When your putting everything back together put the fork back in place and slide the rod back through til you can see the very first clip ring. Put the clip back in place between so that the clip is between the fork and the wall of the case (vacuum side. Also PM me if this doesn't make sense). Now the fork Is held in place but there is a gap between the cable side of the case and the fork. This is where you slide your spring into place so that it is always trying to push the fork out of 4x4. When the cable is pulled it will lock the axel and as soon as you unlock the PTO cable it will slide out of place again.
So there is the basic write-up. Leave me comments if you have any ways to make this better or easier. So far it works quite well(takes a little longer to put in 4x4 but i know its not going to go out)
Last edited by blankdeluxe; 02-06-2011 at 09:49 PM.
#3
CF Veteran
Join Date: Jan 2011
Location: Littleton, CO
Posts: 2,765
Likes: 0
Received 0 Likes
on
0 Posts
Year: 1991
Model: Cherokee
Engine: 2001 4.0L
#5
Junior Member
Join Date: Oct 2010
Location: Kamas, Utah
Posts: 47
Likes: 0
Received 0 Likes
on
0 Posts
Year: 1995
Model: Cherokee
Engine: 4.0
Very nice write up. I am just glad I don't have to worry about that on my XJ. I am sure anyone with an axle disco will appreciate this.
#7
Senior Member
Thread Starter
Join Date: Oct 2010
Location: Pagosa Springs, Colorado
Posts: 562
Likes: 0
Received 0 Likes
on
0 Posts
Year: 88-ish
Model: Cherokee
Engine: 4.0 I6
If your planning this hold off for a couple days. I have to work out a gremlin in the system. The cable stop that I said was my "weak point" in the system came loose already. Im pretty sure I have a fix for it however I'm heading out of town til next tuesday so I cant tear it down til then. Stay tuned.
Trending Topics
#9
CF Veteran
#10
Senior Member
Thread Starter
Join Date: Oct 2010
Location: Pagosa Springs, Colorado
Posts: 562
Likes: 0
Received 0 Likes
on
0 Posts
Year: 88-ish
Model: Cherokee
Engine: 4.0 I6
Come to find out nothing came loose. Its solid inside the case. The PTO cable actually bumped up against the motor and melted plastic inside it so i had to shim it for a couple days til I got the cable fixed. Its working 100% again now.
Thanks Dan!
Thanks Dan!
#11
Senior Member
Thread Starter
Join Date: Oct 2010
Location: Pagosa Springs, Colorado
Posts: 562
Likes: 0
Received 0 Likes
on
0 Posts
Year: 88-ish
Model: Cherokee
Engine: 4.0 I6
for some reason these two pictures disappeared from the build list.
Hey dan, can you add those two to the write up page?
Hey dan, can you add those two to the write up page?
#13
CF Veteran
#15
Senior Member
Thread Starter
Join Date: Oct 2010
Location: Pagosa Springs, Colorado
Posts: 562
Likes: 0
Received 0 Likes
on
0 Posts
Year: 88-ish
Model: Cherokee
Engine: 4.0 I6
posi lock
I'm working on another one right now that is actuated with a power door lock actuator. My brother is an engineer so him and I are working on the details to set this up and mount it.
Basically you will just have to flip a switch in the cab to lock the axle. As soon as we have a prototype together I will get some pictures up.
Basically you will just have to flip a switch in the cab to lock the axle. As soon as we have a prototype together I will get some pictures up.