If your vacuum disconnect axle is intermittant or has quit working entirely... be sure to check the vacuum lines running to the motor. They often pull off and render the disco useless and your rig without 4wd! Look for damage to the lines - any nicks that could allow vacuum to escape will render the motor useless.
Quick fix is easy! Just grab a couple of -long- zipties and secure the rubber vacuum connector to the disco motor housing. Thread the zip-tie between the plastic lines and then under/behind the disco motor housing & snug that thing down! No more 'Disco Fever'! Do the same thing to the connection at the hard line located at frame end of control arm.
If the vacuum lines are damaged then it is time for some TIGHT fitting bulk vacuum hose from your local parts store. Don't use the flimsey stuff as it can collapse under vacuum and again render the vacuum motor useless.
If you have pics of your own repairs or can suggest other methods - please contribute your ideas (and pictures) to this article!
October 31, 2006