For all of you that are sick of your 4X4 going out all the time, or need a quick fix for free, this is my Ghetto conversion to manually shift the transfer case. This involves removing the encoder motor to gain access to the shifter peg on the transfer case, and using a crescent wrench, or open end wrench (i found a 9/16 fits pretty well) to shift the transfer case. or, you could take it a step further (which i am currently toying with the idea) and cut a hole in your floor, and weld, or bolt a rod to the shifter peg.

-First, you will need to remove the front drive shaft, being careful that your U-Joint caps don't fall off, or you may lose your needle bearings, then your U-Joint is screwed. (i used rubber bands to hold mine in place).

-Then, you will need to remove the drive shaft yoke from the transfer case, this involves removing a large nut, and it will be very difficult to remove, i recommend using a breaker bar or impact wrench. (i believe the nut is like a 28mm but im not 100% on the size). Once you have the nut removed, the yoke should slide right out of the transfer case, you may need to "motivate" it a little.

-Now, you will have access to the encoder motor. You will need to remove the wire harness from the motor, and preferably remove it from your truck. this harness goes up near the brake booster, and clips into another harness there. simply unbolt it from the encoder motor, remove it from the clips, and follow it up then detach it at the booster and set it aside for safe keeping, you will want this later if you decide to restore the electric 4X4.

-Now, Remove the Encoder Motor. This has 3 bolts holding it onto the transfer case (10mm i believe). You will see the shifter peg once this is removed.

-Now, you will want to reinstall your Drive shaft Yoke, being sure you tighten the nut pretty tight, (don't have the exact torque spec, sorry) and reinstall your drive shaft.

-Now, you will have the shifter peg exposed. I left mine exposed and found that a 9/16 open end wrench fits onto it quite nicely, and now use that to shift between 2X4 and 4X4. You may also cut a hole into your floor, and attach a rod and use it that way, OR, as i am toying with the idea, find an older blazer, or one with manual 4X4, and use the shifter linkage from that.

Counter clockwise one click will be 4WD HI, counter Clockwise 2 clicks will be 4WD Lo, turned all the way clockwise will be 2WD.

Ive had a few people ask me about this since i have it listed in my signature, so i figured i would make a write up for it. this by far may not be the best method, but its free, and its better than no 4X4 at all.

This was done on a 1994 S10 Blazer 4X4. If anyone has any more info, or pictures, (sorry i don't have any, wasn't thinking about it at the time) i would be glad to add to this write up.
Thanks for looking, and let me know what you think.

 

okay so i did this conversion today
andjust figured i'd add that when you take the
yoke off the transer case you should be ready
cause the fluid from the case is coming at you LOL
at least mine did and i wasn't ready

 

okay so i did this today now i have no lights or clicking when i push the button
my only question is ///is my actuator that locks the front wheels still doing its job or do i need to convert it to a posi-lock cable type system?

 

If you started off with the NV233 transfer case, then yes, the actuator under the battery is doing its job.

But, since the purpose of this thread and this whole section is the articles and their content; discussion of problems with your truck are not appropriate. Please create a new thread on your problem. Do not forget to include the pertinent vehicle information.

 

yeah, sorry, i shoulda added that in there, you will lose a small bit of fluid when you remove the yoke.

 

the electric 4x4 will no longer work when you do this, you have to switch it manually if you did the conversion. your actuator should still do its job, because that is run by vacuum. when you swith the transfer case to 4x4 it opens up the vacuum to the front actuator, in turn locking the front hubs.

 

I did this the other day since neither a new encoder motor or TCCM fixed my truck (was able to take back all the parts though). Now I have 4wd again!

I will note that the driveshaft does not have to come off in some cases. I was able to get the encoder out with mine still in. It's worth a shot to try before dropping the driveshaft.

 

So do you think this mod would workon a 99 bravada? Seeing how my awd has been out since i bought he truck & none of the shops cani ve taken it tell what the issue is.. I do realize that i would onl have 4 hi.

 

bringing back old thread: how hard is it to turn the shifter peg? i tried to turn it and couldnt or i wasnt applying enough strength. i will note the truck was not running if that helps

 

I've dont this before when my encoder motor went out. It took effort but you shouldn't need a breaker bar or anything to move the peg. Make sure you are turning it the right way. Also, auto 4x4 and awd transfer cases work differently and I would NOT recommend doing this mod to them