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Old 10-21-2016, 09:26 AM   #1
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YJ Transfercase problem

Hey guys, I just picked up a 92 wrangler, 4cyl manual. It has a lift. I have no idea if its body or suspension. Its on 33" tires. Ive never had a Jeep I bought it and clearly didnt know what I was getting into. My problem. It has 4low but when i put it into 4hi, it works a little bit (at least it seems like it) then it does some griding and seems like it clunks out of 4wd. I did some reading and they pointed me to the Linkage on the transfer case. I took it off it was rusted solid. After 25 phone calls to regional dealers, I found one. Replaced it and it seems like I am having the same issues, Is the transfercase shot? Or do you think my linkage is still off? I am not a mechanic. But as far as i can tell i have the linkage adjusted correctly.

Thanks for the advice!
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Old 10-23-2016, 11:27 PM   #2
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If it has an excessive body lift or a transfer case drop kit with suspension, that can cause problems with the linkages. You'll just have to fiddle with the linkages until you get what you need

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Old 10-25-2016, 01:11 AM   #3
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Mine had a 2" body lift and a 4" suspension lift when I bought it. The car was a pain to drive... So I removed the body lift, and it drives a lot better. Removing the body lift is not that hard (if the screws aren't tight). Here is a video to install them. This might solve your problem...
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Old 10-26-2016, 10:17 PM   #4
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I would say it's the linkage. One thing you can try is disconnecting the linkage and then put it in 4h moving the selector directly on the t case. . I've had the same thing happen before shifting in and out on the fly dealing with snowy roads. Every once in a while i wouldn't push the shifter far enough and it would pop out. Mine was just caused by the boot on the floor. If you do have a body lift the boot could pushing on the shifter weird too.
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Old 10-28-2016, 12:07 PM   #5
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I dont think the 4wd is engaging, The previous owner had the front axle locked. (modified the actuator to always be engaged) but I dont notice a difference when I shift into 4hi, Turning sharp corners there is no binding or anything that I have experienced with my friends 4wd pickup. So i am assuming that the 4wd is inoperable. Assuming that the transfer-case is junk, What is the cost to rebuild it, I am unsure that I am able do it myself I am not mechanically inclined.
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Old 10-29-2016, 12:30 AM   #6
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Old 10-29-2016, 12:38 AM   #7
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How was it "locked" ? Only a couple ways to do it correctly which is a manual selector instead of the vacuum. Is there a manual lever in the cab or a cable running from the axle? Other mod is the split shaft is removed and a solid shaft is installed. Which in that case the only way it wouldn't work is 4wd is the axle is snapped and free spinning or there are lock out hubs. Are there "selectors" you can turn in the center of the front wheels? Assuming none of that is the case or its all okay you can try free spinning the drive shaft to trouble shoot. In 2 wheel drive the drive shaft shouldn't spin because the front axle is engaged (given what you're saying ). If it spins free then something is not engaged in the front axle. If the driveshaft won't free spin by hand then i would disconnect it from the front yoke (axle side) and then it should spin. You can then while the jeep is off put it in 4wd and then the driveshaft should no longer free spin. If it does then something could be wrong with your shifter on your t case. Usually if something is actually broken in a Tcase it should be obvious. Has the Tcase been modified at all? SYE kit? It is possible to put together wrong when installing an SYE and that has to do with the shifter. I would try all positions as well and understand if it's doing anything at all in 4wd. Meaning put it in 4 low and neutral. Before you start shopping for a fix you need to pin point exactly what's wrong and always remember to check the cheapest fixes first when trouble shooting. If it starts pointing in a more expensive direction you need to be positive.[/QUOTE]
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Old 01-10-2017, 03:56 PM   #8
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should it be easy to move directly on the case by hand?

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