Vehicle: 92 TBI 4x4

Problem: Failed emissions and no 4x4.

So, I started in a likely place. Replacing the vacuum hoses.


Step one, replace the main hose. 7/32" , about 1 foot

http://img.photobucket.com/albums/v448/therealsundance/DSCF0130a.jpg


Here the 7/32" line goes into a series of splitters(arrows)
http://img.photobucket.com/albums/v448/therealsundance/DSCF0131b.jpg


Next you will use 5/32" hose. Replace the line to the vacuum ball. Just follow the hose route and replace.

Warning: be careful pulling all connections as you could break the plastic fitting. I suggest slitting hose.

http://img.photobucket.com/albums/v448/therealsundance/DSCF0132a.jpg

http://img.photobucket.com/albums/v448/therealsundance/DSCF0137a.jpg

Next replace the hose to this item? anyone know what it is?

http://img.photobucket.com/albums/v448/therealsundance/DSCF0133a.jpg

http://img.photobucket.com/albums/v448/therealsundance/DSCF0135a.jpg


All right. Now for the fun part! Replacing the transfer case lines.

Start by jacking up the truck and locating the vacuum connection on top of the transfer case.


http://img.photobucket.com/albums/v448/therealsundance/DSCF0169a.jpg

Pull the fitting out. The easiest way to pull the lines of is to slip it over the top of the case so you have some slack to work with. Remember to slit the lines to pull them off. And mark which line is which.

http://img.photobucket.com/albums/v448/therealsundance/DSCF0170.jpg

Now you must pull the old lines and run the new. The area where the old lines ran up the fire wall is very tight and I couldn't pull the new line through with the old one , so I just ran it in a new location. I used a piece of tie wire taped
to the line to pull them down from the engine compartment.

http://img.photobucket.com/albums/v448/therealsundance/DSCF0172.jpg

http://img.photobucket.com/albums/v448/therealsundance/DSCF0175.jpg

The old lines ran on the other side of the tranny dipstick tube.


Here they are sticking out in the engine bay.

http://img.photobucket.com/albums/v448/therealsundance/DSCF0177.jpg

Now just reconnect them and you are done.

One connection is here:
http://img.photobucket.com/albums/v448/therealsundance/DSCF0131c.jpg


The other is under the battery.

I need toi go back and replace the vent hoses, but I didn't by enough 7/32 hose.

Well if you do that and put them pics up here im gonna vote either for a sticky or into the FAQ section.There is so much talk on this board of vacuum lines and everything that this will help lots of people.Very nice job and i want this stickied/FAQ when the rest is finished.

bump some guys might need to see this