Transfer Case stuck, need help - JeepForum.com
 
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post #1 of 5 Old 11-12-2011, 08:23 PM Thread Starter
96JeepCherokeXJ
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1996 XJ Cherokee 
 
Join Date: Oct 2011
Location: Belleville
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Transfer Case stuck, need help

The jeep is a 1996 Jeep Cherokee 4.0 Straight six with a NP231 Tcase. I just bought this jeep not to long ago so I am trying to get this thing up to par to keep for a long time as a hunting jeep. Anyway I knew when I bought the jeep that it had trouble coming out of 4hi back into 2wd. I got under the jeep and another just like in and realized that my jeep was missing a plate that holds one of the main pieces of the linkage. So I go to the junk yard and spend hours getting the part out of a 94 jeep just like mine with the same tcase and engine. So this weekend I remove the old linkages and put in the plate. I put new grommets on the linkages and made sure I put everything in the right way. Before I did all this I could get the Tcase to go into 4hi but not 4lo so I figured the linkages needed adjusted. But it wouldnít come out of 4hi and back into 2wd using the shifter. I had to get under the jeep and put it back into 2wd by hand. Now that I have the new plate in and everything were it should be it wonít come out of 4hi. So I discounted the main rod going back to the Tcase and tried to put it in 2wd by hand and it wonít move. I can get it in 4lo or 4hi but not 2wd. Itís like it hits a wall when trying to come forward to 2wd. When the linkages are not connected to the Tcase they all work like they should but when hooked up they wonít. So my jeeps tcase is stuck in 4wd. It will go from 4hi to 4lo but not 2wd. Can anyone help with this? Is the Tcase toast or could I have done something to cause this. Oh and yes I did try to put it in 2wd with it running. I also backed up the jeep 50 yards, that didnít work. I tried putting it in different gears while trying to switch to 2wd still with not luck. I have tried everything I can think of to get it to work. Please Help

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post #2 of 5 Old 11-12-2011, 09:20 PM
the_weirdo
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Sometimes a transfer case drop will make the linkage bind up some and make it difficult to shift into 2wd or 4lo. I have had luck removing the faceplate for the shifter (the one that says 2wd-4hi-N-4lo) and using a dremel tool to grind the metal shift gate a little more so that the shifter can go slightly further forward and get into 2wd.
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post #3 of 5 Old 11-12-2011, 10:31 PM Thread Starter
96JeepCherokeXJ
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Join Date: Oct 2011
Location: Belleville
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What did you mean "transfer case drop?
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post #4 of 5 Old 11-12-2011, 11:36 PM
the_weirdo
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When people lift Jeeps (especially 96+) they will either do a slip yoke eliminator (SYE) or put in a transfer case drop to reduce driveline vibrations. You can tell if there is a transfer case drop easily - the cross member that holds up the transfer case and transmission should sit flush with the frame rail. If there are spacers between the cross member and the frame rails, then you have a transfer case drop. Take a picture of the side of the frame rail and the cross member and we can easily tell what you are running.
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post #5 of 5 Old 11-13-2011, 09:06 AM Thread Starter
96JeepCherokeXJ
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Join Date: Oct 2011
Location: Belleville
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This jeep is not lifted, its stock
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