DIY Jeep Wrangler YJ Posi Lock diff conversion

[@Poweraddicts]

Has this tip helped you? Here is a free way to help me. Here is my Amazon influencer page that has many of the parts I've used in videos and some parts that friends have used. www.amazon.com/shop/poweraddicts-fixjeepscom-jeepcarandmotorcycletips?ref=ac_inf_hm_vp . By purchasing through this Amazon page you help me get a small commission of the sale and you do not get charged a cent more. Keep checking back because I update the Amazon page often. Thanks for your support!

[@mattlane2010]

I enjoy your videos so much, thank you for your time and devotion to your KZbin channel! It makes 18-year-old kids with a limited budget like myself able to go 4 wheeling on the weekends

[@Poweraddicts]

Matt Lane My Jeepin' brother .. those are the type of comments that make the time invested into these videos all worth it!!! I really like the fact I help so many people out. Makes me feel good. I try my best to gear my videos for the novice to be able to follow along and do it themselves. Check out the site that goes along with this channel for some great information: www.fixjeeps.com/ . Also, You are very welcome! Thanks for subbing to my channel and taking the time to drop in such a cool comment! Have a great day!

[@brendakay11]

I'm fixing to do this to my 89 cherokee cause the vacuum control changer just works when it feels like working ,which is when I buried the jeep to the axles and no 4wheel drive so as I live in the country and haul wood out of the woods I need something that work when I want it to work .I took 3 hours to dig it out and said this is going to be changed so I looked up your very good videos and have a better understanding of how to do it .Thank you so much for your time and dedication .

[@Poweraddicts]

nicko bowles You are very welcome!! Since I did the conversion, it hasn't failed me once. Even got me home a couple of months ago when I dropped the rear universal joint. Drove her home in front wheel drive. Do what I gotta do to get home!! LOL. Thanks for checking out the video and taking time to leave a great comment!! Have a great day!!

[@brendakay11]

Power Addicts - Jeep, car and motorcycle tips I think I ,with your help,can do this to my jeep and I'm eager to get started ! Thank you again .

[@Poweraddicts]

nicko bowles You are very welcome! There is only one way to learn. That's getting your hands dirty. If you like and got the $$, here is an easier faster option: amzn.to/1DWYbZ8 .. Just a suggestion or go old school modding like I did. Good luck man!!

[@brendakay11]

Power Addicts - Jeep, car and motorcycle tips I looked at these and I would have bought the wrong one ! Thank you bunches for sending the right part for my jeepster.!

[@Poweraddicts]

nicko bowles Glad to help :-) . Take a close look at the fork in the CAD. They are often cracked. Mine has a subtle crack in it not too bad though. I should have replaced it when I had it apart but I wanted it back together ASAP because it's my driver. When I finally get my Mustang back together, there are several larger mods I'm going to do to the Jeep. Good luck and have a great day!!

[@subixbarbarasson157]

Thank you so much. I just bought a 91 YJ. You are a well of wasteland knowledge. Makes my day.

[@Poweraddicts]

Thank you very much!! Glad the videos help. Thanks for taking the time to drop in a great comment!! Have a great day!

[@Msheather0109]

Going to try this tomorrow! My 95 YJ has just been sitting cause its squirrely around 30mph. I had a friend help me figure out the 4wd wont disengage. (most trouble shooting talks about not engaging to begin with) Hours of videos and research to figure out what it might be. Glad I know how the system works now. Hopefully this is the fix I need! Its my first Jeep and had it about a month an only been on the road a few times. Your videos are very helpful, thank you. And thank God for TN weather so I can work on my Jeep in the winter. : )

[@Poweraddicts]

You're welcome, glad you like the videos! I now run my front diff locked all the time. That little shift fork that slides the collar to engage the shaft, it broke, so I locked the shafts together full time. It shouldn't make it squirrely. Does it feel different while driving slow speeds? Yes, it does, but it doesn't hurt anything. Just makes turning tight turns feel a bit different. I'd start checking the tie rods and other front steering parts. If any of those are loose and worn, it will cause crazy low-speed steering issue. Which means it can create more dangerous issues at faster speeds. Good luck! Congrats on buying a Jeep! Have a great day!!

[@Msheather0109]

Actuator was very clogged! Working on the cable system now... wish I could post a pic... lol

[@Msheather0109]

Already did most of the front end parts :) in my driveway ... just need it stable enough to drive so I can get to the Alignment place.

[@Poweraddicts]

Send the pict to the facebook page: facebook.com/fixjeeps/

[@Poweraddicts]

I've learned that the good thing about my YJ .. It's so easy to work on. Parts aren't crazy expensive either. Hope the one you are going to check out is good for ya! They are a lot of fun .. and addictive to drive!

[@kparrottsr]

thanks so much for the video. the setup worked great. the only thing i did different is i drill and tapped the yoke to a 1/4-28 thread and made a low profile eye to hook the cable into works better than it ever has. koodos to you

[@Poweraddicts]

Karl Parrott Great job! Since I did the mod, it has never failed me. Thanks for checking out the video! Also thanks for sharing a great suggestion! Have a great day!

[@Poweraddicts]

+Zack Seal I wanted to reply directly off of your comment but there wasnt an option.Anyway ...That cable I used in that video turned out to be shorter that I thought,it's probably 4ft. I have since picked up a choke cable from the autoparts store which is much longer and will work much better. Just havent installed it yet. Hope that helps. Thanks for dropping by and have a great day!

[@mathiasdearaujo473]

hey man i have a jeep yj 1994 my 4x4 wasnt working but u video helped me to fix it. thank you very much . and i almost bought a hard drive. hahaha thank you man

[@zurue99]

thank u sir saved me 100 bucks now i got beer money 89 yj 2.5 squirrel powered

[@Poweraddicts]

+Chris “xurue” Small Glad I could help you save some money! That conversion hasn't failed me at all. You feel it when it locks in. Thanks for a great comment! have a great day man!!

[@MattJoinesVietnamWarAirsofter]

+Chris “xurue” Small I have the same year and motor lol

[@TheWoodWerker]

Hey whats up from Huntsville! I just bought a 94 YJ about a week ago. Love it! Thanks for making your vids Man, really helpful! I subbed and liked!.........Gus

[@Poweraddicts]

Hey hows it going from Nashville!! Man, my little YJ is probably my most favorite ride I've ever had (besides my bikes). Glad you like the videos! Thanks for the sub & like! I've got a some projects in store for the YJ as soon as I get time. Stay tuned and have a great day!!!

[@jeepcollector91]

Great video & great mod. You can also remove the CAD and install a one piece right axle shaft from an XJ or TJ Dana-30. You do have to install an inner axle seal for that side since the seal is currently at the CAD for that side. I am gong to eliminate the entire thing on mine by installing a Dana-30 that I pulled from a '98 XJ. Also gets me larger axle shaft u-joints. Just a matter of welding on the leaf spring perches. I just need to catch up on some other projects first. You can get XJ Dana-30's for $60-$120 at the U-Pull salvage yards in my area. If you get lucky you can also get an XJ Dana-44 rear for around the same price.

[@Poweraddicts]

I've read about the TJ axle convert, definitely an option to look into . Too bad I scrapped an explorer a while back before I got the YJ. It had an 8.8 under it that I could have gotten for free to upgrade the rear! I've got a set of 1 tons from an old black Chevy that I used to have. Its on my site http:\\www.poweraddicts.com. They are a bit overkill for the Jeep considering its a DD. I get too good of gas mileage to hurt that. I get about 21 highway in a fun to drive ride. Have my cake and eating it too!!

[@jeepcollector91]

PowerAddicts That 8.8 would have been a great free upgrade since you already had it. I had an 8.8 (welded spiders) and Dana-30 from a 2.5L Jeep YJ both w/4.10 gears in my '91 for a short time along with a 4" RC lift. Removed everything and went back to stock (even reinstalled the Dana-35) then parked the Jeep for a few years. Considered going "overkill" also. I have an '86 Chevrolet M1008 just sitting going to waste (bad 6.2L). That Dana-60 & 14-bolt w/4.56 gears and a Detroit locker would have worked great in the YJ. Would have also been very heavy and required more power. I decided to keep it light, low, reliable, and drivable instead. As well as keeping decent MPG's. Now it only has a 2.5" RE lift (gave almost the same lift as the 4"RC) and I am staying with 32's (265/75R16) this time around. I just need to get back to work on the '98 XJ Dana-30 & '87 XJ Dana-44 axle swap 3.55/3.54gears for the YJ. Hopefully never to go back to stock again.

[@whitelsc]

Question, would this allow for 2wd low? Another plus would be if I had this option I could weld the front end locked for wheeling and still have it open for road use right?

[@Poweraddicts]

Rob Nusekabel Drop in 4 low and not locking the front diff will get you 2 low. As for welding the front, if you do that you will loose the 2wd low that you mentioned first. This is because by welding the front gears you basically turned the front diff assembly into a full spool. I don't promote welding gears unless its a full trail rig. Thanks for checking out my video, have a great day!

[@ZenNiklaus]

Welded mine. And as mentioned above, without the axle posi lock engaged I have the driver side spinning while not actuated. Which honestly has helped in tight situations while in 4low. You can just engage and disengage the axle when you like.

[@70dejavu]

Great job thanks for the video, Im going to look at that 92 on Saturday I hope its as good as it looks

[@812williams]

Whats your thought on doing the same thing on my 91 jimmy? but just hooking up a old school choke to the cable going to the front where the crappy vacuum boot is?

[@juliusmclauchlin7280]

Great video. I have a 2001 Dodge ram 1500 that had the same set up. My 4x4 isn't working either and I think it's because of the actuator so I'm going to attempt the same thing you did in your video. Thank you for the idea. I'll post how mine turned out later on. Oh and just a stood question but why cant the axles just stay engaged ? Why do they need to disengage ? Just wondering

[@Poweraddicts]

julius mclauchlin Some people run with the axles engaged. One popular conversion for the YJ Wranglers is to put the TJ axles in the tubes to eliminate the CAD all together. I tried running mine with the axles engaged. It felt like I was pushing my front tires around tight corners. I didn't like at all the way it felt while driving it. So I disengaged the front diff and it felt normal again. Also some people report that the feel the vibrations from the front drive shaft spinning. Now that I did the manual conversion I don't have any issues at all with the front diff engaging or disengaging. I just engage them when needed. Oh .. one point, the cable I used in this video was a bit shorter than i liked. I got a crazy long choke cable from an auto parts store to replace the shorter one. So be sure you get a cable that's longer than you actually need. Thanks for checking out my video and taking the time to comment. Have a great day!!

[@MrDanoconnor]

Great Video Man, One question Please... When you pull the cable to engage the 4x4, does it line up and engage all the time or do you have to kinda move the jeep a little to make the spline line up and go into place while pulling on the cable? If that's the case then you can't put it in 4 wheel when sitting still... Right? you have to have some movement to engage the spline on the axle?? Would really appreciate you explaining... thanks so much.... DanO'

[@Poweraddicts]

Thanks, glad you like it! What I typically did was. I'd stop, pull the cable and slowly inch forward. That would allow the collar to engage smoothly. I now have the collar locked in permanently. So, I removed the cable since I didn't need it anymore. Here is the video where I locked the collar over: kzbin.info/www/bejne/gGfPoGpnf5d_qqc . Thanks for dropping in! Have a great day!

[@beanzackery0109]

I did this on my yj and it worked pretty good but honestly just get the passenger side tj axle and get rid of the vacuum actuator all together. Your still going to have problems with it down the road.

[@Poweraddicts]

I have thought about doing that. If I ever run across an axle I might do it. I locked my CAD in full time and it felt like I was pushing the front end around corners. I unlocked it and left it where I could lock or unlock at will. So, I'm really on the fence about it. I haven't had any trouble at all with the convert since I did it. After the convert, the only other issue that could arise is the CAD fork break. But, they tend to crack whether its with the vacuum actuator or Posi Lok convert. So agreed, running the TJ axle does do away completely any issue that could arise. Thanks for dropping in a great tip to share with others! Have a great day!

[@dropshop]

Question my wrangler is just for the woods..mud.. deep puddles.. in other words I don't drive in street if i mod it to lock full time is it bad . Also is the rear locked of do i have to mod ot also. Thanks.. your videos are awesome learned alot for a newbie

[@Poweraddicts]

Full locked on dirt and mud will not be too bad. It will make it harder to make sharp turns. It does put more stress on the axles. You can do one axle or the other or both. It's strictly a play toy, I'd do both. Best option would be to get something like these great but inexpensive lockers. amzn.to/1FsvWUh . You can still drive on the street, yet have great traction when needed. Hope this helps. Thanks for dropping by and really glad you like the videos!! Have a great day!!

[@franksinatra1018]

Thanks for the great video! I’m getting ready to do this repair on my YJ. Just to verify, I will still shift into 4-High or 4-Low as normal, then engage this new switch? Thanks!

[@rhull3939]

Yep

[@zackseal149]

hey man...how long is that cable you used? the only ones i could find was 4ft long and it doesnt look like it will reach

[@opensmsm8260]

Nice video chuck! but i would like to ask, why we don`t make it locked ? i saw a guy on KZbin wondering why Jeep made the front excel with on/off lock?!! (separated wheels) what happens if we leave it locked all the way? i saw some put a spacer in it!!

[@davidjessee7701]

open smsm it just saves on wear and tear..less moving parts , better fuel mi.

[@66windar]

Great idea! Did you just cap off the old vacuum lines down to the canister?Cause they'd be still trying to pull air one side or the other

[@Poweraddicts]

+Darwin “windar66” Ewins Yep .. just cap them off and let 'em ride. This mod has worked flawlessly every time. Just make sure the cable you buy is long enough put the handle where you want it. Thanks for dropping in! Have a great day!

[@66windar]

Power Addicts - Jeep, car and motorcycle tips thanks for the informative info!Great vids!

[@Poweraddicts]

You're very welcome! Thanks for checking out the vids!

[@vinnierock079]

I did this and am now leaking fluid from the actual cable shield? any other problems with this? other than that, it works fantasticl

[@Poweraddicts]

I used RTV inside the coupling when I tightened the brass fitting. Also used the outer cable cover (hose) RTV and clamped it. I had no issues at all. I broke the shift fork about a year ago. I locked the collar in place so now it's locked in full time. I'm gonna do a video soon as to how I locked the collar in place. Super simple and CHEAP!!

[@davidjessee7701]

Check your axle seal..

[@YourPledge]

Nicely done! thank you

[@Poweraddicts]

Our pleasure!

[@williamwerner7599]

Did you end up removing the switch on the transfer case or just capped the lines?

[@Poweraddicts]

+William Werner Just capped the lines. Sorry I didnt mention that in the video. Thanks for dropping in! Have a great day!

[@cpt.redbeard3383]

how much length was this cable and how much length did you have left over, slack wise?

[@Poweraddicts]

+Patrick Thomson I didnt realize until after I had run that cable through the floor that it was a tad short. Best cable that I have found so far is using an old school automotive choke cable that can be had at most local auto parts stores. The choke cable is much longer then the lawnmower throttle cable. Still to this day that conversion is working great. Thanks for dropping in :-) Have a great day!

[@francescosuarez]

So since my posi lock won't engage 4x4 and the light doesn't show up in going back to stock vacuum since my vacuum is all working properly, if not ill just use 2 clamps and lock the dif with the stock actuator so the light works lol

[@Poweraddicts]

That light just annoys me, I take the bulb out so I don't have to look at it.. Its easy to tell when you are in 4 wheel drive.

[@francescosuarez]

@@Poweraddicts well i don't feel nothing engage i tried going reverse etc . But since I have vacuum in stock hoses I bought the complete oem 4wd actuator so ill remove the posilock

[@shootgun33]

hey I was just wondering which way the fork on the vacuum goes to lock it in 4lo? I'm killing my jeep this weekend at a mud bog so it won't need to come out of 4lo. I can slide the gear right but not to the left of the axle. Just wondering which way I need it to lock onto to keep it in 4lo.

[@Poweraddicts]

Slide the collar away from the passenger tire toward the center chunk. That will tie the axles together. But, the low gearing is determined by the transfer case, pull the t-case shifter all the way back puts you in 4low. The collar simply locks the axle shafts together.

[@shootgun33]

+Power Addicts - FixJeeps.com - Jeep, car and motorcycle tips Thank you!! She's locked in now. Tcase was already in low and still works fine. I can lock it in and out by hand now lol. Just gotta take the cad cover off

[@Poweraddicts]

The collar will not stay by itself. Something has to hold it in place or it will slide back over. I've done a trick where you take 2 hose clamps. Put a clamp on each side of the collar to prevent it from sliding back over. Effectively locking the front diff full time. The main thing to watch is: one - stagger the worm screw of the clams 180 degrees from each other on each side of the collar, This prevents the front shaft from being thrown out of balance and vibrating. Two - make sure the clamps are TIGHT .. but do not strip the band or worm screw of the clamp. Some people are freaked out by doing this mod .. so its up to you if you want to do this. I'll make a video of the mod sometime soon.

[@shootgun33]

+Power Addicts - FixJeeps.com - Jeep, car and motorcycle tips Hey man. I think she will stay. The plunger is rusted to fuck and takes quite a bit of force to slide it over lol. If not I will just slide it back over after someone drags me out of the hole hahah

[@Poweraddicts]

LOL .. have fun! My Jeep has been dragged out, even with the front diff locked. I was buried to the frame. All in good fun :-)

[@Poweraddicts]

Check out the website that goes along with this channel: www.fixjeeps.com/ #fixjeeps

[@brendakay11]

I installed the posi loc assembly you suggested and it works soo good ! I live in central In. and got it done the night before we got 7 inches of snow.Oh what fun ! Thank you again .

[@brendakay11]

nicko bowles The headliner and death shake are next !

[@91YJDestroyer]

What did you do about the vacuum line to the t case or engine?

[@Poweraddicts]

All the vacuum lines are still plugged up like original. Inside the vacuum can of the CAD I packed gasket sealer around the edges and inside the vacuum port. This prevents water from entering where the diaphragm is now missing. Also the gasket sealer prevents vacuum leaks from where I plugged the CAD vacuum line back in place. The 4x4 light works. Pull the cable to lock in the CAD, pull the t case into 4 wheel drive. Everything works great now. Thanks checking out my video and asking a great question! Have a great day! :-)

[@mattwhalen9553]

So on my jeep where the vacuum lines hook in I can take that whole thing and do a 360 spin with, been hearing a knocking sound where unit is when at stop light. What do you think is broke in it??

[@Poweraddicts]

There is a fork that slides a collar to engage the splines. That fork is made of some cheap metal. Very prone to breaking. If it does break, the collar will "float" and will catch the axle splines causing strange noises. I've also head of that fork popping against the spline after breaking. All you can do is pull it off and look. It should be obvious pretty quick.

[@mattwhalen9553]

Ty

[@Poweraddicts]

You're welcome :-)

[@kevindeibler346]

I know this has nothing to do with this video but do you by any chance know what to do with the sticky Door latches on half doors

[@Poweraddicts]

Spray the internals with sprayable lithium grease. It helps a lot!!

[@kevindeibler346]

Power Addicts - FixJeeps.com - Jeep, car and motorcycle tips thanks looking for to more videos on project rust bucket

[@LifeofCrane]

How far back did you remove the vacuum lines?

[@Poweraddicts]

I removed all of them. Capped everything off.

[@edsonbarrios9746]

Hi, I have a yj 90 I would like to know what function the vacuum actuator fulfills, mine is with a broken hose, but my 4x4 works

[@Poweraddicts]

Well, its supposed to be to move the fork to connect the 2 piece axle shaft. If you have a vacuum line broken, without seeing it, I have no idea how your 4 wheel drive is engaging.

[@davidjessee7701]

If your four wheel drive works but your vacuum is broke , its probably stuck to the left or the driver's side..

[@richardwhigham9201]

Should my 4 wheel drive light come on when I slide the lever over.

[@Poweraddicts]

Slide the "lever"?? Or you mean the t-case shifter?

[@isaacjacquez2689]

or do the. $.50 cent fix.. drill tap bolt in an hold the shift fork in place.. until you can fix it properly

[@leeevans8454]

is it necessary t pull the plunger apart?

[@Poweraddicts]

Most cases, no you dont have to pull it apart. That one was dragging so I wanted to see what was going on inside the diaphragm area. It must have been all that built up crud inside that area. Once I cleaned it out it moved much better.

[@leeevans8454]

awsome. good to know. got a 96 ram that could use this treatment. thanks.

[@Poweraddicts]

Thats right, I forgot about the full size Dodges using that vacuum pot. Suggestion, get a long old school choke cable instead of the throttle cable. The throttle cable will probably be too short. You can get the choke cable at most autoparts stores. Good luck!!

[@HeCute_]

How do you engage 4lo?

[@Poweraddicts]

By the transfer case shifter. This mod doesnt alter how the transfer case works.

[@camcordernonsense5264]

so interesting. I have to force myself to stop watching. I must sleep!

[@Poweraddicts]

Don't worry ... get some sleep. My videos will be here when you get up!! LOL

[@edwinconcepcion4060]

Donde lo puedo rncontrsr

[@patrickming4854]

what is the plug to the left of the actuator

[@Poweraddicts]

+Patrick Ming It sends the signal to the dash light indicating the 4x4 is engaged.

[@patrickming4854]

Thanks I just git a Jeep yesterday first one 94 model

[@Poweraddicts]

Patrick Ming Welcome to the Jeep addiction! I like all Jeep Wranglers, I seem to prefer the YJ generation due to their simplicity. Congratulations .. you will love it! Thanks for dropping by! Have a great day!

[@davidjessee7701]

I'm guessing you don't have a front locker ? If you did have a front locker even if you don't connect the front axle ,you would have been able to drive in four wheel drive ,even if the rear drive shaft was removed, you would still have one wheel pulling in the front.. wow that's a mouth full..

[@Poweraddicts]

No locker yet. Coming soon hopefully. I've had to drive it home in "front wheel drive". Dropped the rear driveshaft one night. I toss the driveshaft in the Jeep. Pulled her back in 4 hi .. drove her home. Thanks for dropping in and leaving a great comment! Have a great day!!

[@Poweraddicts]

No locker yet. Coming soon hopefully. I've had to drive it home in "front wheel drive". Dropped the rear driveshaft one night. I toss the driveshaft in the Jeep. Pulled her back in 4 hi .. drove her home. Thanks for dropping in and leaving a great comment! Have a great day!!

[@bobhernandez7756]

How does the oil get to the cad ?

[@Poweraddicts]

It just runs down the axle tube