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Old 11-14-2011, 02:53 PM   #1
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Transfer Case Pops out of gear

I have a 2000 TJ. Sahara. 4" suspension lift. Right before I bought it the dealership that I bought it from installed a new drive chain in the transfer case. I also have a slip yoke eliminator.

When I am in 2 hi and my tires break free you can hear the transfer case gears grind and it pops out of 2 hi momentarily. and it wont stay in 4 hi or 4 low long enough to shift gears or put any type of load on the transfer case. I also have problems shifting from 2 hi to 4 hi at any speed, it grinds horribly.

I am going to try the adjustment of the linkage and see if that helps. I am just curious if this may be another problem that the dealer ship may have cause when they replaced the drive chain.

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Old 11-14-2011, 04:22 PM   #2
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Where does ur transfer case jump to wen its in 2hi? And another think. When goin to 2hi to 4 hi don't be goin faster then 25mph and also don't give any gas. My truk will grind to if my foots on the throttle....

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Old 11-15-2011, 03:32 AM   #3
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I feel like it jumps in between 4hi and 2hi. and it grinds at any speed when trying to shift from 2 hi to 4 hi from 0 to 5 mph and higher.
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Old 11-15-2011, 08:22 AM   #4
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Your linkage might not be letting your TC shift fully into gear. An easy way to test that is by removing the nut holding the linkage to the TC and sliding the linkage off. You can then use a small box wrench to shift the TC into gear and try driving that way. If it stays in gear fine you know your linkage may need adjusted/replaced (Novak shifter cable is a good option). If it still jumps out of gear, I'd say the people who worked on it messed something up.
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Old 11-15-2011, 09:25 PM   #5
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I think it is your 4X4 linkage. You will need to crawl under the drivers' side and look up by the tranny while somebody else shifts into 4hi and 4lo. The linkage is an easy fix and has some room for adjustment. It is a common problem after lifting.
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Old 06-12-2013, 04:32 PM   #6
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I'm having the same issue with 4 low and the guy i just bought it off of has a 2 inch body lift on it would that cause the linkage to not engage the whole way?
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Old 06-12-2013, 04:43 PM   #7
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My daughter's jeep does the same thing after a 1" body lift, and it looks like the linkage is off some and doesn't want to stay in the correct position. I would suggest getting what I just ordered from Savvy: the Novak cable shifter. $172 delivered and it replaces all of that linkage. reviews on it are great.
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Old 06-12-2013, 05:21 PM   #8
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I too shall recommend the Novak cable shifter. I installed mine because of major engine and trans swap over and subsequent binding of the stock lever and rod setup. The Novak installs simply, uses the stock shifter, minimal adjustment time, and bada boom, bada bing....very smooth and positive shifting. Can't beat it!
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Old 06-12-2013, 05:44 PM   #9
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Hey thank you guys. Appreciate the help.

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