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Old 07-05-2009, 12:46 PM   #1
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Unhappy 4wd not engaging for '99 TJ 2.5L

Need some help folks.

Got my '99 TJ 2.5L 5-spd about a year ago with 150,000 miles. When I bought it, had a mechanic do an inspection and he specifically answered that the 4wd is working fine.

I never used the 4wd since I bought it and tried to couple of times over the last 4 months.

Problem: When I switch into 4H, all I hear is a regular thump like the it's trying to switch into 4H but it never doesnt actually switch, noise continues, and no 4wd light on the dash either.

Any ideas what it could be? What I could check for before taking it to the shop? I assume it's something with the transfer case but dont know what to look for.

Thanks in advance.

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Old 07-05-2009, 01:11 PM   #2
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It sounds like the transfer case shifter mechanism has just slipped out of adjustment. There's a single bolt that holds it in adjustment underneath and if the shift rod that bolt holds slipped, it won't shift into 4x4. I'd crawl underneath with a flashlight and while someone shifts for you, watch the mechansim (which is exterior to the transfer case) to see how it works. After watching it, you should be able to see how it works within a few seconds and determine if it has simply slipped out of adjustment.

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Old 07-05-2009, 04:18 PM   #3
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Jerry - I got under the Jeep and had someone pull the 4wd shifter. I could see the shifter mechanism moving but it "seemed" normal to me, but I wasnt sure what normal looks like so cant be sure that whether the transfer case shifter mechanism has slipped out of adjustment.

Any other tips, hints, things I can check?
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Old 07-05-2009, 04:30 PM   #4
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When you were checking it was the t=case shifting in to gear?

The linkage down there is connected to a lever on the t-case. The rod going into the lever "shifter linkage" can be out of adjustment and not letting the t-case ingage.

On the rod there is a bolt that tightens down apon the rod. To adjust it just loosen the bolt and slide the rod forward or rearword and then tighten the bolt back.

Also to do this you can pull the lever back into 4LO and disconnect the rod to the t-case lever...manually place the tcase in 4LO with your hand to insure it is indeed in 4LO and re attach the rod and make any adjustment to the rod to get it to line up with the tcase lever.
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Old 07-05-2009, 04:47 PM   #5
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When my helper pulled the 4wd shifter from 2H to 4H, I saw the linkage mechanism move. I also noticed that the arm connecting into the T-case was also moving.

Again, I have no idea if it's actually shifting inside the t-case, but the linkages seems to move.

----

On a side note, there is a protective metal coverings of sort that runs across the bottom of my Jeep and seems to be connected to the rest of the frame by bolts.

Is it advisable to remove this for ease of view and work under Jeep?
Also, how heavy and hard would it be put it back on?

Once I do this, I'll have a much better view of the underbody and t-case.
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Old 07-05-2009, 07:24 PM   #6
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Just because the linkage moves and the lever is moving some doesn't always mean it is moving "all" the way into position. The adjustment rod can get moved and not be in a correct position. When you loosen the bolt holding onto the rod you can move the rod back or forth to adjust the location it is held on the rod and tighten the bolt back.

The "protective metal covering" would be your transmission crossmember also know as trans/t-case skid plate. If you remove it you better have a jackstand or floor jack under the transmission. That crossmember holds the transmission and tcase up. And as for the wieght of the crossmember ...probally 45 pounds or so.


Also a few question for you..

1. Is the vehicle at a complete stop when shifting into 4H or 4L?
2. How did you test the 4wd to tell it is not operational?
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Old 07-05-2009, 08:00 PM   #7
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I would note the direction the shifter rod is pushing the short lever on the transfer case when your helper is attempting to shift into 4Lo. Then loosen the bolt (it takes a 1/2" wrench) that holds the rod and use a pair of pliers to move the short lever on the transfer case more in the direction the rod was pushing it and it'll likely click all the way into 4Lo. Now with the lever on the transfer case all the way in 4Lo and the transfer case shifter lever in 4Lo, tighten the snot out of that bolt using your wrench. The shifter linkage should now be properly adjusted.
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Old 07-05-2009, 10:27 PM   #8
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Thanks for your patience and help thus far...

Quote:
Originally Posted by distortedtj View Post

The "protective metal covering" would be your transmission crossmember also know as trans/t-case skid plate. If you remove it you better have a jackstand or floor jack under the transmission. That crossmember holds the transmission and tcase up. And as for the wieght of the crossmember ...probally 45 pounds or so.
Am I supposed to remove the skid plate before trying to loosen the bolt and push the rod all the way back?

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Also a few question for you..

1. Is the vehicle at a complete stop when shifting into 4H or 4L?
2. How did you test the 4wd to tell it is not operational?
1. I've tried to shift into 4H and 4L from a complete stop and starting with 1st gear. I've also tried to shift into 4H at about 5-10-20 mph usually in 2nd gear. I just hear "clunk clunk"...nothing for about 3-4 secs and again "clunk clunk".

2. See #1. Am I trying to shift into 4H the wrong way? I've never actually gotten any vehicle in to FWD.
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Old 07-06-2009, 01:42 AM   #9
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Your shifting it alright.

No need at all to remove the skid to adjust the linkage. I'd actually suggest not removing it for this.

Just some FYI on shifting into 4wd.....

To shift into 4H...this can be done on the fly up to 30/35mph..although I'd suggest a much slower speed...you can even do it stopped.

To shift into 4L...pull the lever all the way back into postion best done at a COMPLETE stop in neutral or cluth pushed in...sometimes it helps to be rolling 1 or 2mph to engage.
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Old 07-06-2009, 01:49 AM   #10
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Something I have not yet seen mentioned is the shift motor. Make sure your shift motor is connected and functioning. I had an XJ where my shift motor got disconnected somehow and the 4x4 didn't work. One ziptie later and I was shredding mud with all my buddies.
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Old 07-06-2009, 02:09 AM   #11
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Quote:
Originally Posted by Jiffydarren View Post
Something I have not yet seen mentioned is the shift motor. Make sure your shift motor is connected and functioning. I had an XJ where my shift motor got disconnected somehow and the 4x4 didn't work. One ziptie later and I was shredding mud with all my buddies.
If your refering to an axle shift motor....Not on a TJ Dana 30... YJ's and some XJ's yes.

The TJ uses high quality bearings that have very low resistence so it doesn't use hubs or an axle disconnect system. Where the YJ and or some XJ's used a vacume or electric disconnect/connect rod to engage the axle.

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Old 07-08-2009, 10:10 AM   #12
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Sorry to butt in on techie214's post...

But i have recently adjusted my shift linkage. In the service manual it tells you to tape an 1/8" drill bit to the back of the shift handle and bump it all the way back to 4Lo, the drill bit ensures an 1/8" gap between the shift handle and the end of the 2H 4H 4Lo "track".

So i got under the jeep. found the lock bolt and the linkage.

Before this process my shift handle was about 1" from the end of the track (4Lo), when i loosened the lock bolt and tightened it back up, looked in the cab and the handle was 1/8" from the end of the track, sitting on the drill bit. Success! right? NO, the reason why i made my adjustment was because 4H would engage but it would slip out, under a small load or bouncing around a bit, 4Lo stuck in just fine. So after my adjustment offcourse 4Lo still worked fine, but 4H still will slip out. Also in 4H the shift lever is about 1" from the end of its track, it's like it could still be pulled back more, there is quite a gap. can i do the same adjust ment for 4H that i did for 4Lo? too eliminate that gap? Also if i can and do will it mess up the 4Lo lock in???

p.s. the jeep has about a 1.5" body lift, the guy i bought it from had just put it in and hadn't adjusted the linkage after. This i why im doing it, and why i hope the 4H was slipping out.

HELP

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