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)

 

Good write up, and thanks for the links.

 

i do believe this looks like spam........and not the good kind!!

 

LMAO!


OP, Great post! Well written!

 

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.

 

Very nice! Gonna have to do this soon

 

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.

 

Good write up;
Any more progress?

 

And he's outta here! Please report when you guys see em so the staff can perma ban their ars.

But this is a good write up. Think I'm gonna submit it into the write up section

 

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!

 

for some reason these two pictures disappeared from the build list.





Hey dan, can you add those two to the write up page?

 

BD;
Thank you so much for this great write up. I'll probably do this to mine, the alternative is the $215.00 kit!

 

oh wth?
I'll do it after work

 

I don't see anything missing...
Maybe another staff member did it and didint tell anyone?

Who the hell did it?! That was my job! LOL

 

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.