QU10569 New Process Transfer Case Vacuum Switch for Dodge and Jeep

QU10569 Transfer Case Vacuum Switch is an aftermarket replacement part for most Dodge and Jeep 4x4 vehicles with New Process NP231 and NP241 Transfer Cases equipped with a vacuum controlled Central Axle Disconnect (CAD) system. The switch is typically threaded into a port on the upper side of the transfer case above where the transfer case shift lever is located. The internal valve directs vacuum between the engine source and front axle CAD shift unit. Use with QU10800 O-ring.

Need More Info? Use the handy Links below to access over 40 years of Dan's product and vehicle specific Tech Notes to easily get the information you need for your vehicle's repair, maintenance, or upgrade project!

Dan the Gear Man® Tech Notes:
Troubleshooting
CAD Engagement Issues
Vacuum Leaks
Matching Parts
Applications

Tech Note 1: Troubleshooting
Troubleshooting axle disconnect problems can be tough if you do not have patience, a vacuum pump and vacuum gauge. Quite often, by the time you decide you can not live with erratic shift performance, the original issue has caused one or more further difficulties. Shifting problems can be vacuum, mechanical, or both. To help you understand the vacuum system, TSB4903 color coded vacuum schematic will soon be available in the future. We are also working on Tech Service Bulletin 4904 Diagnosing Vacuum Controlled Disconnect Problems on Dodge and Jeep Vehicles to help you troubleshoot the many possible sources of shifting problems. TSB4904 will be released as soon as I can get it done, but in the mean time, I am semi-retired, so unfortunately, I am no longer available to help you troubleshoot your CAD system over the phone or via e-mail.

Tech Note 2: CAD Engagement Issues
If you are having Central Axle Disconnect engagement problems, there is usually multiple causes. Some of the most common issues that need to be checked are (and part numbers for most Dodge applications):
Vacuum Shift Motor Leak: Unit will not hold steady vacuum. Replacement is required.
Bent Vacuum Motor Shift Rod: Replacement is required.
Worn Axle Shaft Bushings: Replacement is required, see QK4625, QK4646, QK4626.
Differential Output Shaft Splines Worn: Replacement is required, see QU40300, QU10943.
Stud on End of Differential Output Shaft Worn Undersize: Replacement is required, see QU40300, QU10943.
Tips of Shift Collar Splines Worn: Replacement is required, see QU40246, QU40274.
Shift Fork Bent or Pads Missing: Replacement is required, see QU40156, QA4628, QK4760.
Vacuum Line Leak (VERY common on these older trucks) : See QU11061, QU10942, and QU11062
Transfer Case Vacuum Switch Bad: Replacement is required, see QU10569

Tech Note 3: Vacuum Leaks
A common problem cause of vacuum leaks at the switch is swelling of the rubber 4 port connector that fits over the transfer case switch. Just about every truck with an engine oil leak will have this problem if the oil is blown onto the connector for any length of time.

Tech Note 4: Matching Parts
Exploded View XV4000 1994-1996.5 Dodge Ram NP241DHD Transfer Case
Exploded View XV4001 1996.5-1997 Dodge Ram NP241DHD Transfer Case
Exploded View XV4003 1998-2002 Dodge Ram NP241DHD Transfer Case
Exploded View XV4002 1994-1997 Dodge Ram NP241DLD Transfer Case
Exploded View XV4004 1998-2002 Dodge Ram NP241DLD Transfer Case
QU10800 Vacuum Switch to Transfer Case O-Ring
QU10942 Main Vacuum Harness, 1994-1997 Dodge Ram all with CAD
QU11061 Main Vacuum Harness, 1998-2002 Dodge Ram all with CAD
QU11062 Frame to Axle Vacuum Line Kit 1994-2002 Dodge Ram all with CAD
QU50831 1995-1997 NP231D Front Case Half for Dodge Dakota and Ram 1500
QU11142 1994-2002 NP241DLD Front Transfer Case Half w/ wide bearing for Ram 2500, Ram 3500
QU50636 1994-2002 NP241DLD Front Transfer Case Half w/ narrow bearing for Ram 2500, Ram 3500
QU50591 1994-1997 NP241DHD Front Transfer Case Half for Ram 2500, Ram 3500
QU11143 1994-2002 NP241DHD Front Transfer Case Half for Ram 2500, Ram 3500
QU11223 1994-2002 NP241DHD Bare Front Case Half for Ram 2500, Ram 3500
QA4628 CAD Shift Fork Kit
QU40317 CAD Shift Housing
Dodge & Ram Shop Manuals
Jeep Shop Manuals

Applications

Dodge:
Ram 1500: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001
Ram 2500: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002*
Ram 3500: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002*
*2002 NP241DHD/DLD using these assembly numbers: 52105027AC, 52105028AC

Jeep:
Data to be added as time permits