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Old 03-25-2016, 07:00 AM
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Transfer Case Linkage

I'm running a 7.5" RockKrawler long arm kit I welded in myself in 2006 and a 1" BL on my 2000 TJ, 5 speed manual I6.

I went to install the Teraflex linkage drop bracket to level out the shift linkage arm. When I 'popped' the linkage arm out away from the bracket on the body, the grommet, boot and maybe something else just vaporized. Literally they weren't there anymore.
Looks like the round brass bushing in there is fairly shot.

I am waiting until I have funds to get the Novak conversion. So, in the meantime, shouldn't I be able to simply crawl under there and shift that lever AT the t-case to engage 4wd? Somebody tell me what's on...
Thanks in advance~

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Old 03-25-2016, 07:08 AM   #2
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A factory linkage rebuild kit is around $13 at the dealer.

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Old 03-25-2016, 12:21 PM   #3
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Yes you can engage by hand
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Old 03-25-2016, 03:27 PM
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I know the factory rebuild kit is $13; I looked at it. However, I cannot figure out what order the pieces/parts go on the horizontal rod to the body mount. And I haven't found any good exploded view of parts online that shows that order.
I tried putting the green replacement grommet in there, but that one doesn't seem to work or I'm not putting it in the right place.
If anyone knows the order to put those parts in before that rod goes through the hole in the bracket, please share! Thanks
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Old 03-25-2016, 08:49 PM
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Also, can someone please explain exactly HOW I can simply crawl underneath and "manually" shift that metal tab/lever AT the t-case to engage the 4wd?
Would be much appreciated!
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Old 03-25-2016, 09:06 PM   #6
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Don't recall exactly as I did it to my old '99 a few years back. What went where, but with your setup you're bound to keep breaking them. I found these which I believe will give a general idea and I think you can find instructions on the Crown site for their kit, which should be useful too.



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Old 03-25-2016, 09:26 PM   #7
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Quote:
Originally Posted by Fuji_san View Post
Also, can someone please explain exactly HOW I can simply crawl underneath and "manually" shift that metal tab/lever AT the t-case to engage the 4wd?
Would be much appreciated!
I don't have a 231, but I believe 11 or 12 o'clock position of lever is 2 wheel hi. Rotating it CCW will incrementally shift it to 4 wheel hi, neutral, and 4 wheel lo.
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Old 03-25-2016, 10:08 PM
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Great thank you I will try. Now do I have to engage the clutch?
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Old 03-25-2016, 10:26 PM   #9
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Engaging the clutch would only put more bind in the drivetrain, but if you're alone, slip the tranny in neutral and try it. Just follow the same procedure you would if using the cab lever.
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Old 03-25-2016, 11:14 PM
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More bind on the drivetrain...that makes sense. The only time I tried to do this, my buddy was stepping in on the clutch. So, I'll do the 'neutral' trick and try CCW rotation on the shift tab at the t case. Sure hope that works. Need to make it through a few more snow storms before I can afford to get the Novak cable adjuster.
Thanks again Waterboy
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Old 03-25-2016, 11:18 PM
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UFO,
I found that same diagram but sure couldn't figure out what I was looking at after I broke that connection apart from the body mount.
I'm gonna try and find another 97-2000 TJ near me with manual and check out their linkage
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Old 03-26-2016, 08:30 AM   #12
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What part of linkage do you want a picture of

My 98 sport is a 5 SPd with factory linkage and no body lift or engine lift or tc drop but it does have a 4" spring lift so easy to crawl under and snap a pic or 2
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Old 03-26-2016, 04:09 PM
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Digger,
It's the rod that runs horizontally alone and second rod down the linkage from the top. So the first rid is the one with the square but that's adjustable. The second is oriented perp. and runs into the body mount bracket. There's like a tear-drop shaped wing-style metal piece with a brass bushing/ball inside there. It's def busted. And then there's a grommet to the bracket but it popped out when I pulled the assembly to drop the rid down.
I don't know how it all fits back together at that point.
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Old 03-26-2016, 04:18 PM   #14
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Does this pic help or you want something else

Basically the body mount pivot of the linkage
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Old 03-26-2016, 04:52 PM
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That's the spot Digger, thanks. Hard to tell what's in there, looks like mine did when I removed it.
Basically everything fell outta that one spot. So I cannot tell where the grommet goes and if it fits in front or behind the bracket, or if the grommet is green or black. Seems like the two colors are same/very similar...
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Old 03-26-2016, 04:59 PM
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Hmmm, after looking, looks like that rod goes through the body bracket hole; and no grommet there

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