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Thread: homemade posi lock

  1. #1
    Join Date
    Nov 2008
    niagara falls
    Time Online: 1 Wk 5 Days 7 Hrs 32 Mins 53 Secs
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    homemade posi lock

    I just got done with the home made Posi Lock because the vacuum unit went out, which I am sure a lot of you know how that goes. I tried finding a detailed (idiot proof) write so here is mine, for us idiots.

    First the parts:
    -NAPA 9ft Locking Cable, part 731-1104
    -1/4" Compression Union
    -5/8"x2-3/4" Compression Spring
    -Zip Ties
    -Piece of Metal 2"x3" roughly
    -Rivets or Screws
    -Gasket Maker
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    -Socket Wrench
    -Various Sockets
    -Various Box Wrenches
    -Jacks and Jack Stand
    -3/8" Drill Bit
    -7/16" Tap
    -Various other drill bits
    -Rivet Gun

    1. Jack the front passenger side up. Place on jack stand. Take off tire.
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    2. Loosen and remove 4 bolts on front axle fork cover (in red). Release weather pack (in blue). Pull off vacuum lines (in green). Place oil catch under working area.
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    3. Remove whole assembly, be careful with the gasket so you can reuse it with a little gasket sealer. See picture for whole assembly.
    Click image for larger version. 

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    4. Drill a 3/8" hole one the left side of assembly. Hole size may vary with compression union.
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    5. Tap whole with 7/16" tap. Again tap may vary.
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    6. Drill a small whole in the fork, as small as you can get. Mock up whole assembly. Screw in compression union center, place in spring, place brass ball washer and nut on cable (don't tighten the nut onto the brass ball washer real tight until later). Place spring in and bend the cable wire slight. Test the locking cable by pulling the t-handle, make sure in shifts correctly.
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    7. Take it all apart now.

    8. Find a place to mount the t-handle. I placed mine to the right of the steering wheel with diamond plate. You can mount it any where you want. Rivet or screw down plate. Screw down handle to plate. Thread the cable through the fire wall. I drilled a small whole through the main wire loom gasket.
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    9. Thread the cable around the back of the motor and zip tie down. I place mine on the heater hose because if I need a few more inches of slack its there. I have a ton of slack down near the axle so i doubt I will ever need this slack. I may move it to another location after some 4x4ing. You can mount anywhere you like. Route cable down to passenger side of axle.
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    10. Place the cable locking assembly back together. Tighten down the compression nut with the brass ball washer make sure the cable is in there nice and tight. Bend the cable wire and make sure it does not slip.

    11. Place the cover back on insuring you have the fork lined up with the axle shaft collar. Put some gasket maker on the gasket. Tighten down bolts. Reconnect weather pack, vacuum lines to make it pretty. Place some gasket maker on the end of the compression union around the cable. Zip tie the cable to the axle make sure you have enough slack for articulation.
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    12. Check your work by chocking the wheels, turn the Jeep on, place in neutral, place t-case in 4wd, and engage the posi lock. The passenger hub should not turn. If it does check your slack in the cable or the shaft collar and fork.

    i can't take credit for it, it was on another forum
    I just thought it was useful and i will be trying it out
    1987 yj, 44 front, 9" rear, ramsey winch, 38.5" Boggers
    360ci, BACK IN ACTION
    1996 Grand Cherokee Limited, STOCK .....BOOOOOOOOO

  2. #2
    Join Date
    Jan 2007
    Sudbury Ontario
    Time Online: 6 Days 10 Hrs 27 Mins 10 Secs
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    theres a write up in the old section of the forum [below parts wanted ] might of saved you some trouble .

  3. #3
    Join Date
    Mar 2007
    near sarnia
    Time Online: 6 Days 17 Hrs 22 Mins 38 Secs
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    hey coulross, thanks for the write-up, I have all your pics saved and will be doing this once spring comes.

    Everyone is entitled to be stupid, but some abuse the privilege

    jeep...Just Empty Every Pocket

  4. #4
    Join Date
    Mar 2007
    Exeter, Ontario
    Time Online: 2 Mths 1 Wk 2 Days 14 Hrs 25 Mins 39 Secs
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    Don't need the info, but thumbs up for a very informative and well made up how to post!
    90 YJ. 4link F/R, 16" SAW Airshocks, 32bolt Beadlocks, D60/14bolt, Full Hydro/Hydroboost L67 3.8SC 700r4 NP231/D300
    02 Yukon XL on 37's DD
    91 Cherokee Juggy scrapped for Greener Grass
    I prefer to build it and not buy it, you see it, I probably made it.

  5. #5
    Join Date
    Apr 2009
    St. Catharines
    Time Online: 3 Wks 3 Days 13 Hrs 54 Mins 15 Secs
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    Bump it up

    And great thread !!!!!

  6. #6
    Join Date
    Mar 2009
    My Mood
    Time Online: 11 Mths 3 Wks 21 Hrs 35 Mins 14 Secs
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    Moved to mini build for more exposure, stickied, and linked in YJ FAQ.

    Excellent write up.
    His ---> 04 LJ - 4.0L, Auto ɹnoɟ pɐǝɹʇǝɹ
    Hers ---> 75 Renegade Project - 304 V8, T15 3 speed uoıʇɐıɔossɐ ʎq pɐǝɹʇǝɹ

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