So i just replaced the input shaft seal on my transmission and I am now trying to replace the 4x4 vacuum switch. I should have waited until the switch came to put the transfer case back in, but I’m stupid or something so i didn’t. I cannot get this darn switch to thread in. I’ve been sitting here for an hour just spinning it. Has anyone who’s done this job ran into this problem? Am i just supposed to keep spinning it until I get lucky and the thread catches? I have looked around and no one talks about this so I’m not sure if I’ve done something wrong.

 

I believe you'll need to make sure that the t-case is in 2HI so that the switch is not activated. If it is activated, you will have to press it in to compress the return spring inside the switch to get it to thread in initially.

 

So do i have to turn the car on, plug the lines into the switch, and then try to thread it in?

 

I seriously cannot get this damn thing to thread. i’ve tried every angle, every possible way it could go in and it won’t thread. It keeps doing this thing where it feels like its threads and I twist it more and it comes out. This should not be the hardest part of this job and yet it is. I am losing my mind. What am I doing wrong??

 

Simple things first. You have compared new & old to make sure they are the same, correct?

As to what I said eariler and your question, you would not have to start the engine, but will need to make sure that the encoder motor is plugged in and then turn the ignition to run to check what mode the transfer case is in. Nothing needs to be attached to the vacuum switch to do this. If it is in 4HI/4LO, then there will be a cam lobe inside the transfer case that is there to push out on the switch. 2HI, this cam will be rotated to its base circle and not exerting much pressure on the switch.

 

Yeah i compared the old and new and they are the same. I can’t get the old one in either. I’m pretty sure it’s in 2HI but I’ll try it.

 

No dice. I’m wondering if I have to pull the T case which sucks because i literally just put it in and sealed it.

 

Ive had the same thing happen. For me I had to turn on the car. And if any of the lights on the 4wd switch you will have to put it in 2 high. Like he was saying if it’s in a 4wd mode the cam in the t case will be in the way. If there is no lights on your 4wd switch you need to figure out why there is no power to that. For me the problem was a loose connection on. The back of the switch. Once you get it into 2 wd it will thread in like a breeze.