Alright, my transfer case is VERY difficult to shift into anything other than 2Hi, and when it finally does get into a 4WD range (after much grinding) it immediately pops out of gear.
This is very irritating. I'm assuming this is because of the shift linkage based on my searches, but I have no idea what to expect in repairing this (I'm digging into it tomorrow morning). Anyone have any advice about how to properly fix this issue?
(I've already searched, and looked over the FAQ's)
93 YJ 4.0 HO with AX-15, NP231, RE 4" Lift, Stock Axles, BFG 33's, Posi-Lok'd, and Herc'd
Verify your flud level is correct. If so, referring to Joe's pic above, you can just pry-pop the linkage rod off. It is rubber mini-gromet mounted at both ends. Once one end is popped off (the rear is best), you can shift the linkage by hand (probably with channel lock pliers to help) and see if you still have the problem. If you do, it's an internal issue. If you do not, it's a linkage issue. If linkage, that 1/2" bolt on the front end of the linkage rod is an lock bolt. That bolck on the rod slides fore/aft as needed to get the nength right, then is locked down to that length.
Remember, the lever action makes the t-case shifter backwards. Full back is 2hi. Full forward like this pic shows, is 4lo.