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Old 01-27-2010, 07:56 PM   #1
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4 wheel drive lever linkage adjustment

My 4 wheel drive level keeps jumping out of 4 wheel drive, and I can't seem to get the linkage adjusted to make the gears happy. I put the transfer case in 2wd hi, and it starts to grind a little once I've driven a ways. Then I move it into 4wd hi and it stays in until I let up on the gas then it pops out. I put the transfer case into 4wd lo and then adjusted the lever to be in the correct position, and it runs fine in 4wd lo, then when I put it in 2wd hi it tends to grind slightly when driving.

Anyone know how to make this adjustment? I'm getting frustrated!

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Old 01-27-2010, 08:36 PM   #2
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Per the service manual:
1. Shift transfer case into 4L.
2. Loosen lock bolt on adjusting trunnion.
3. Ensure linkage rod slides freely in trunnion. Clean rod and apply spray lube.
4. Verify transfer case range lever is fully engaged in 4L. (Having another person hold the lever fully in the 4L position helps here.)
5. Tighten adjusting trunnion lock bolt.
Assuming your problem is simply an adjustment this procedure should work well.

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Old 01-27-2010, 09:15 PM   #3
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Thanks Chip,
I did all that already. When the lever is in 2wd hi, it feels like the lever should go down a little farther than it does. But also when it's in 4wd hi it seems not to stay engaged. What is up with this thing.
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Old 01-27-2010, 10:50 PM   #4
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Do you have a body lift? A BL without the adapter bracket installed will give those symptoms. If BL/bracket isn't your issue I'm out of ideas.

As a side note when I'm in 2H the lever is a bit mushy and does feel like it could go farther forward but I think it's just play in the linkage.
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Old 01-27-2010, 11:53 PM   #5
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Mine use to pop out of 4 low on occasion, I did the adjustment per the manual, and it got worse. I did the adjustment a 2nd time, this time using a bungie cord to keep the handle all the way in 4 low, and it hasn't popped out since.
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Old 01-28-2010, 10:19 AM   #6
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I can here the gears like they are not working together. I get that clunk, then zing of the gears out of sink? Maybe I'll try to fuss with it again later to day.

Thanks for all the help.
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Old 01-15-2013, 05:18 AM   #7
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Hi guys, I experience the same issue, had it linkage fixed and it does continue. The only way us to go to P and shift 4L there. Then it stays. This means its an automatic transmission rotating also when on N. It shall be re adjusted or wait for having it warned out more (in my case). I have to say I had the trans repaired after haveing water there... Re Manual, I do not know.

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