My 97 TJ is fine in 4WD but when I take it out and back in 2WD with out stopping it sounds like its still engaged then BANG it comes out. Maybe its vacuum but I dont even know where to start looking.
The TJ doesn't use vacuum anywhere in the 4x4 system. Try backing off on the gas when shifting back into 2wd and see if that helps. How's the ATF level inside the transfer case?
My 4wd does that occasionally as well when the jeep is moving. It's not too loud of a bang but its audible. I dont really worry about it, most of the part time vehicles i've owned have done the same thing when they're in motion. Just bring the speed down a bit and let off the gas and it should help.
About the 4wd light, there is a little hydraulic sensor thats screwed into the transfer case. My TJ had the same problem when i bought it and i ended up bringing it back cause it was still under warranty and they changed out that sensor. I think it's like a 25 dollar part, and the light works perfectly now. I'd imagine its pretty easy to change yourself, the mechanic showed me the old one and it was threaded and just looked like it screwed into the t-case somewhere. I'd imagine once you find it you just unplug the harness that connects to it, removed it with a socket wrench, and then put a new one in and plug in the harness again.
dont use the 4wd on the road, that banging noise is the t case unwinding i believe, when the front or back goes less distnace than the other the T case has to take that, it makes the T case smie bind, btu not completely so when you put it into 2wd that pressure is realeased witha bang, my guess is your using the 4wd on pavement when this happens and also taking turns and going farley fast?
If you're talking about 4Hi, that's pretty silly to think you have to stop and shift into neutral. It's a shift-on-the-fly system that allows shifting in/out of 4Hi at any safe speed, which really means you don't have to stop and shift into neutral to shift in and out of 4Hi.
do you have an auto tranny?
when i shift from 4H to 2H it sometimes needs 30-60 seconds until it really goes to 2H with a quiet "bang" like yours.
when i turn the auto tranny to N while driving before shifting the TC from 4H to 2H it shifts immediately without a bang.
i use my 4wd shifter like its just another shifter. up here in northern ny roads go from inches of snow to dry roads within a block. i throw it back and forth u just cant do it under load or while breaking
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