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Old 08-27-2013, 10:49 PM   #1
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Long shot question re: Range Leve on TC

Forgive the story here. Lots of detail.

So when I bought my TJ, the guy had jimmied up a rod to the TC to manually shift the TC into gear. I'm trying to hook it back up properly, but am having difficulty.

First, my TJ is a 2003. I know the linkage changed at one point from a plate design on the TC to a 2-bent-rod design. So it is possible the pre-2000's (?) are different.

So for those with the newer design that is mounted with this bracket:
https://encrypted-tbn2.gstatic.com/i...6cu5nQfBRVzByC

... I am wondering a couple of things:

1st: Does your range lever (lever attached to the TC) have a rectangular cutout that goes the same direction as the lever itself, or is the cutout diagonal? Like this:

http://www.jeepforum.com/forum/attac...icture-008.jpg

My second question: Does your lever swing upward or downward? So, is 4 lo with the lever all the way down, or with the lever at a horizontal position? Or, heaven forbid, all the way up?

Here's the deal:
If I position my lever downward, I get 2 high and 4 high only. The lever does not move any further because it hits the TC before it gets to neutral. If I position the lever upward I might get all gears, (I got 3, but could fiddle with the adjuster maybe), but then the gears are backwards.... meaning the lever in the cab is all the way up for 2hi, and all the way down for 4lo. This leads me to believe the range lever on the TC should be all the way down when in 4lo. BUT, in order to do that, I would need a cutout which is diagonal as per the picture above.

The part # I have has "405" stamped on it. I just don't think it's the right part.

Anyone have an intimate knowledge of this part on a newer TJ? Or, at the very least, can someone with a 2001 or newer look at the lever when in 4 lo and confirm if it is all the way down? Even that bit of information would *almost* confirm I should have the diagonal cutout, which would allow a greater range of motion before the lever hits the TC.

Thanks!

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Old 08-28-2013, 11:08 AM   #2
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Nobody has a newer TJ they can look at for 1 minute to let me know the TC lever position in 4 low?

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Old 08-28-2013, 11:28 AM   #3
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Quote:
Originally Posted by Reznor View Post
Nobody has a newer TJ they can look at for 1 minute to let me know the TC lever position in 4 low?
4 low is all the way up if that helps if u need a pick of the linkage my tcase is out Laying in my garage the linkage is all hooked up on it I can get a pick when I'm home later
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Old 08-28-2013, 12:04 PM   #4
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I think you're talking about the lever in the cab? I'm talking about the range lever actually bolted to the TC itself. If your range lever is all the way up in 4 lo then I'm in real trouble.
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Old 08-28-2013, 12:52 PM   #5
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Originally Posted by Reznor View Post
I think you're talking about the lever in the cab? I'm talking about the range lever actually bolted to the TC itself. If your range lever is all the way up in 4 lo then I'm in real trouble.
Ha well I'm really not sure off the top of my head ill check when I get home should be in a couple hours so ur talking about the initial link like the first one coming off the t case?
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Old 08-28-2013, 12:55 PM   #6
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It's got to be right after neutral though 2 hi 4 hi neutral than 4 lo
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Old 08-28-2013, 01:34 PM   #7
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On my "99", 231 tc, the lever on the tc is all the way to the rear when in 4L. The torque shaft (between the tc and the tub) has the linkage connection arm that attaches to the gear shift lever facing up, and the one that attaches to the transfer case linkage facing kind of down and toward the rear.

I just looked up a picture in the 2003 FSM, and it's identical to my 99. You can see it if you go here: http://www.jeep4x4center.com/knowled...ex.htm#service type in your year etc. then go to Transmission/transfer case 2, then page 21-225.
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Old 08-28-2013, 04:05 PM   #8
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Thanks guys - figured it out. Like I said in my initial post, the problem is that when the lever on the tc (called a "range lever") was all the way down, it was still not 4lo. The lever required more movement to engage 4lo but the lever couldn't move any further without hitting the tc. I did some research and saw that 231 range levers varied a little from year to year, so I went to the wrecker today and got the lever off a 1990 XJ, which had a diagonal cutout for where it attaches to the tc. This provided me with the range of motion I needed, and the 4wd works flawlessly now.

Seems to me that this particular lever was put on by someone who had no idea, and when he couldn't get it to work he just said "screw it" and sold the jeep as-is.
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Old 11-21-2013, 08:43 PM   #9
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This sounds exactly like my problem 02/TJ/4.0/manual5, I had to have my TC replaced while on the road out of state and it hasnt shifted correctly since, although it would engage in all gears at various times, grinding happened almost all of the time and it never felt secure. I adjusted as much as any one man should do, replaced rear bushing (bad anyway,)to no avail. I was wondering of it came down the range lever position, and how to correct, it sounded as if it was barely gear on gear. Same problem?

Thanks
Mike

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