Dodge
Installation Instructions
Posi-Lok Part No. 400
Pre-Installation Information
These Instructions have been designed for “Unaltered” vehicles. Before you start, check for any variations. Each vehicle may dictate it’s own
control mount and cable routing. Therefore, you will need to study the pictures and use your good judgement or seek professional help. Lift kits
may govern how and where the cable is routed. Always keep the cable away from heat (exhaust) and rough or sharp edges. If you are concerned
about lower cable damage or abrasion, we recommend cutting a length (about 3 feet) of 5/8” ID plastic or rubber hose (garden or heater) to be
slid over the cable before assembly. Please keep in mind, NO WARRANTY on heat damaged or abused cables.
Before drilling, check for any electrical wires, hoses, etc.
Special Tools
You will need RTV silicone sealant, vinyl electrical tape, a 5/8” drill bit (Unibit #3 works best), a 5/16” drill bit and a 9/64” drill bit.
Jacking
Support the vehicle frame with the front wheels off the ground, with wheels at full travel. (Use jack stands and all safety precautions.)
Vacuum
Before you remove the CAD vacuum actuator, locate source of vacuum to transfer case switch and plug off as close to engine source without
disrupting any other vacuum requirements. Use vacuum cap supplied.
Fork Upgrade
When you unbolt the CAD cover, some gear lube will run out. Inspect the fork and fork clips (wear pads) for any replacement necessary. Please
note the direction of the fork offest. At this time, you can upgrade the aluminum fork to a cast iron fork (if not already done) Dana #41553 or
Mopar #4137727. Be sure to order new clips or wear pads with the new fork Dana #621059 or Mopar #4137731. If you choose not to upgrade,
now is the time to remove the OE fork from the vacuum CAD for later installation. Also, inspect the axle splines and collar for wear and repair
as needed.
Save these instructions and place with the Owners Manual, along with the operating instructions.
Note: At this point, it is easy to see why sometimes (50/50 chance) you will not have full engagement until something (shaft or wheel) moves
to allow splines to align. You are the power source and that’s what gives you the control - the last 1/4” of cable travel is the most important!
Switch Wiring
Without switch on CAD:
Make up a 5” lead with #8 and 1/4” lug terminals
With switch on CAD:
Cut off OEM terminal end, add #8 terminals to wires
1/4” to upper cover mounting bolts
OE wires, either wire to
either terminal
Route up to OEM vacuum switch
cut & splice to OEM wire
cut line
Fold Line
5/8” Hole
1”
6.5”
Do not move hole too far to the right, you may hit
the web brace on the engine side of the cowl.
cut line
Template: Transfer to stiff (Manila) paper and cut out.
Page 1
Copyright c 2001 4x4
1 Posi-Lok
Patent # 5,605,213
Hook
line
Fold up
Fold up
cut line
cut
Hold flat and parallel to aluminum throttle support casting
Dodge
Installation Instructions
Posi-Lok Part No. 400
Dash Installation—Step One
Total cable travel is approximately 1”.
1. Remove screw [FIG. 1-A] and drill out the hole to 5/
16”. Hook template over throttle cowl clip, as shown,
and hold the fold flush with aluminum throttle casting
to mark hole, Figure 2-B, and drill out to 5/8”. If
drilled too far to the right (passenger side) you may hit
a web support in the engine side of cowl.
A
2. Install dash bracket on cable by removing Tee handle
cap nut with seal [FIG. 1-A] Do not lose washer inside
cap nut. It may be necessary to bend bracket for proper
hole alignment. Place bracket in between two small
blocks of wood in a vice and tap down with a soft face
hammer or lift up with a marring tool.
FIGURE 1
3. Route cable through cowl hole and slide heat shield
tube over cable. Hold the heat shield up close to cowl
and pull cable through hole, under steering shaft and
route outside the frame rail in front of bumper support
[FIG. 3-A] and over the top of the differential to the
CAD unit.
Throttle
Clip
4. Cut grommet (on one side) to form a “C” and thread in
cowl hole around cable. Loosely mount Tee handle
bracket to dash with 5/16” bolt with nut inside dash.
Unlock Tee handle and push all the way forward.
(Disengaged position.)
5. Slide heat shield tube up to cowl grommet and mark
cable at bottom end of shield. Remove dash bracket
from dash and push cable through to grommet. This
will allow easy access under fender well to install
shield to cable. Move heat shield up in cable about 1”
above mark and wrap bottom end of shield (approximately 3/4” tape on shield and 3/4” on cable) to cable
with electrical tape, then secure tapped end with tie
strap over tape around heat shield and tighten tie strap
to cable.
B
FIGURE 2
Cable-A
6. Now pull cable back and attach to dash, recheck that
heat shield is flush to cowl, then tighten dash bracket
to dash.
B
FIGURE 3
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Dodge
Installation Instructions
Posi-Lok Part No. 400
Differential Installation—Step Two
1. Remove vent tube adapter, if used, or install 1/8” pipe
plug. Clean threads, apply RTV sealant and install new
cover along with the brass switch adapter and switch.
(Do not allow RTV to get on switch ball.)
Cable End
2. Assemble jam nut on cable conduit then place fork into
new cover [Figure 4] and thread cable end into cover
and fork, before installing 3 “E” clips. Recheck that
fork is correctly installed. Now install the 2 “E” clips
on the cable side first, then the last “E” clip on the
switch side. Be sure you are right, “E” clips are hard to
remove and easily lost. Standard “E” clip part is #E-37
Heavy Duty.
FIGURE 4
3. Thread Cable into cover about 1/2” (Use RTV Sealant).
Now push Tee handle into full disengaged position and
turn to lock. See that Tee handle does not hit dash
bracket nut. Pull tee handle to full engaged position and
turn to lock. Check to see that stop “E” clip is resting
against cover housing, this is the full engaged position.
Adjust by turning cover on cable threads and be sure
fork shaft does not touch cable thread end, but “E” clip
is touching cover. [Figure 5]
Collar
4. Align axle collar with axle spline, [Figure 5] rotating
front drive shaft or wheel will help [See Pre-Installation
Notes]. Install gasket and align fork fingers into collar
groove and bolt cover to axle housing with OE shield.
Do not use RTV on gasket as it will cause gasket to
distort.
FIGURE 5
5. Tighten cable jam nut. Hook up switch [See Wire
Diagram on page 1] and vent tube.
6. With front wheels still off the ground, drill a 9/64” hole
for the cable clamp and install [Figure 3-B].
7. Turn key on—with the engine off, place transfer case in
4x4 mode and test front axle CAD engagement and
disengagement. Also test light operation. You may need
to rotate the drive shaft or one wheel a few degrees to
achieve full engagement - the last 1/4” is very important.
8. Lower the vehicle and place nylon spiral wrap over the
cable at the point of wear on differential housing.
9. Check gear lube level. Read operating instructions and
road test.
10.Recheck cable routing during each service job to see
that it is not hitting the drive shaft or steering shaft.
Severe wheel travel may require some readjustment to
Fork Shaft
FIGURE 6
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Dodge
Installation Instructions
Posi-Lok Part No. 400
Operating Instructions
Moving Vehicle
Additional Information
1. Relax Throttle—No acceleration or deceleration.
1. Be gentle but firm. Always use good judgement.
2. Shift transfer case to desired 4x4 mode. Be sure the transfer case is
engaged before you engage the 4x4 Posi-Lok. The system is easier
to engage at slower speeds with the steering pointed straight.
2. The 4x4 Posi-Lok will allow you to have 2WD-Lo Range—which
is great for trailer maneuvering on hard ground. Engage the
transfer case into 4WD-Lo Range, but do not engage the 4x4 PosiLok. (Do not apply excessive torque to this mode.)
3. Gently but firmly pull out Tee handle (approximately 1”) Light onoff throttle will help align the gears for smooth engagement.
3. Do not drive on hard surfaces with the transfer case in 4x4 mode,
with the Posi-Lok engaged. Read vehicles owners manual. It is OK
to drive on hard surfaces with the transfer case in 2x4 mode-with
the 4x4 Posi-Lok engaged.
4. While holding Tee handle in locked position, twist Tee handle
firmly to secure. Remember the last 1/4” of engagement is critical.
Recheck if necessary.
4. If you use a Differential Gear Locker in the front axle, the 4x4
Posi-Lok will allow you to manually unlock the front axle to make
very tight turns on hard ground, then re-lock and move on, thereby
reducing the area needed to make tight turns or back and forth
jockeying.
5. Now use 4WD and 2WD at operators’ will engaging and disengaging the 4x4 posi-lok.
Parked Vehicle
1. It is best to have engine running with the transmission and transfer
case in gear with the brakes locked. You are trying to match splines
that are not synchronized.
5. You must always lock the Tee handle in the engaged or disengaged
position to prevent cable creep.
6. As long as the 4WD light in lit, the level of performance for the
Anti-Lock braking system is reduced. The 4WD light will remain
on—when the front axle is locked, however, you are not in 4WD
until the transfer case is engaged. Read vehicles owners manual.
2. Gently, but firmly, pull out Tee handle (approximately 1”). If cable
will not fully engage, STOP!
3. While releasing the brakes to allow drive train movement, continue
to pull the Tee handle firmly to secure.
4. After moving vehicle, recheck for full engagement. Remember the
last 1/4” of engagement is critical. Recheck if necessary.
Label Sample
5. Now use 2WD and 4WD at operator’s will.
Disengagement
1. Unlock Tee handle and gently, but firmly push cable in to full
disengaged position, then twist Tee handle firmly to secure—
otherwise 4x4 light will remain on.
2. Place transfer case in 2WD mode. (Slower speeds are easier to
disengage.)
Caution: Do not disengage the transfer case before disengaging
the 4x4 Posi-Lok.
Manufactured by 4x4 Posi-Lok
Note: If moving light on-off throttle action will help to relax the drive
train. On some models it is easier to disengage if you stop and
back up a few inches to relax the drive train lock-up, while
pushing the cable in.
404 Jay Street
Coldwater, MI 49036
517-278-7453
www.4x4posi-lok.com
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Dodge
Installation Instructions
Posi-Lok Part No. 400
Limited Warranty
4x4 Posi-Lok company warrants to the original retail purchaser that the 4x4 Posi-Lok is free from defects in material and/or workmanship for one (1) year from purchase date when used under normal operating conditions on light trucks and SUV’s. The warranty does
not apply to 4x4 Posi-Lok Products that have been improperly applied or installed. The consumer will be responsible for removing
from the vehicle and returning to 4x4 Posi-Lok and defective item(s) with shipping costs prepaid. A copy of the original sales receipt is
required for all warranty claims. The consumer may contact 4x4 Posi-Lok at (517) 278-7453 in order to receive a Returned Goods
Authorization prior to shipping. Ship the item, freight prepaid, to: 4x4 Posi-Lok, 404 Jay Street, Coldwater, MI 49036, along with a
copy of your sales receipt. 4x4 Posi-Lok will, without charge, repair or replace at its option, the defective item(s). The item will be
returned with transportation costs prepaid within the U.S.
Limitation of Warranties
The loss of use of the product or vehicle, loss of time, inconvenience, commercial loss or consequential damages are not covered. 4x4
Posi-Lok reserves the right to change the design of any product without assuming any obligation to modify any product previously
manufactured.
This warranty gives you specific legal rights and you may also have other rights which may vary from state to state. Some states do not
allow limitations on how long an implied warranty lasts or allows the exclusion or limitation of incidental or consequential damages,
the above limitation or exclusion may not apply to you.
There are no warranties, expressed or implied, including any implied warranties of merchantability and fitness, which extend beyond
the face hereof. Seller disclaimers implied warranty of merchantability.
Limitation of Liability
4x4 Posi-Lok’s liability hereunder shall not exceed the purchase price of the product. 4x4 Posi-Lok shall not be liable for any incidental or consequential damages, whether direct or indirect, including, but not limited to, personal injury, property damage, economic loss,
loss of profit, or the like. 4x4 Posi-Lok shall not be liable for any damages or defects of any kind whatsoever after installation of the
4x4 Posi-Lok, unless the purchaser has complied with any and all installation instructions. The limitation of liability as set forth above
shall apply even to claims of negligence or strict liability against 4x4 Posi-Lok.
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