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Unread 04-05-2015, 08:53 AM   #1
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
Zj Transfer Case Problem Help!

So i just wanted to start by saying i'm new to this form and the jeep scene so please bare with me and hello all fellow Jeepers! So i have read a lot about transfer case problems and know there is a lot of post on this form and yes i've read a lot of them but still cant seem to fix my problem. I am starting to fear i may just end up needed to buy a new transfer case.

When i first got my jeep it was stuck in 4WD High yes it still runs and drives and doesn't crab walk to bad i would like to fix this before i break something else.

Things i've tried-
Looked over vacuum lines they all looked fine and no leaks that i can see i will do a more detailed look today.
Tried the whole dirt road 10mph Neutral then shift out of 4WD and it didn't help still wouldn't move.
I have tried putting it into other gears it will go into Neutral and 4WD low but sometimes it will grind and doesn't want to stay in gear.
I checked the linkage cable plastic bushing and changed it didn't really help.
It also doesn't seem like my leaver is being stopped by anything causing it not to move into 2WD.
I filled and check all my tires and tire pressure everything is set to same PSI and all tires are same size and width.
I still haven't checked the fluid of even tried to change it yet it is on my list of things to do tho.

I am starting to run out of ideas and things to do before i just go buy another transfer case. So any advice or ideas i would love some help.

93 zj 3' lift on 31s

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Unread 04-05-2015, 09:16 AM   #2
reydelaplaya
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1996 ZJ 
 
Join Date: Nov 2010
Location: Cuatro Esquinas, Puerto Rico
Posts: 184
Welcome to the forum, and welcome to Jeeps - they can be fussy at times, but they're usually worth it.

Mine would pull this trick from time to time. There's an adjustment screw on the side coming down from the 2WD/4WD lever. Scribe where it currently is, then loosen the screw so that the selector lever moves freely. Pull the selector lever to 4-LO and tighten the screw. Now try putting it in 2WD.



If it works like mine did, you'll just need to then find the adjustment sweet spot where the lever and the 2WD/N/4Hi-Lo finally match up by repeatedly loosening the screw and moving it around.

If this doesn't work, let us know.
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Unread 04-05-2015, 09:49 AM   #3
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
Ok thanks for the quick response i am going to go try it now i will keep you updated was also thinking about trying to blow out the lines one might have some crud in it if this doesn't work.
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Unread 04-05-2015, 10:06 AM   #4
Taz360ZJ
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Join Date: Nov 2011
Location: , N. MN
Posts: 588
what transfer case do you have?
__________________
Slate 5.9 Limited 8"/ARB/IRO/KOR/OME/231
White 5.9 Limited stock/231/30's
'93 ZJ SE 5.9 clone
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Unread 04-05-2015, 10:28 AM   #5
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
so i loosen the screw and it still wont move freely 4d40 was used on it even tried to genitally hit it with a hammer it still wont move
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Unread 04-05-2015, 10:30 AM   #6
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
249 J transfer case
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Unread 04-05-2015, 10:32 AM   #7
reydelaplaya
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1996 ZJ 
 
Join Date: Nov 2010
Location: Cuatro Esquinas, Puerto Rico
Posts: 184
Quote:
Originally Posted by CoreyZj View Post
so i loosen the screw and it still wont move freely 4d40 was used on it even tried to genitally hit it with a hammer it still wont move
It's an exposed part on the bottom, sometimes they seize up a bit with road crud n stuff. Soak it with some wd40 and let it sit for a few.

BTW, does your linkage look like my pic, or it it different?
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Unread 04-05-2015, 10:33 AM   #8
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
it looks the same and the bolt is currently out and i sprayed everything with wd40
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Unread 04-05-2015, 10:35 AM   #9
reydelaplaya
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1996 ZJ 
 
Join Date: Nov 2010
Location: Cuatro Esquinas, Puerto Rico
Posts: 184
You mentioned blowing out the lines.

If yours is like the pic I posted, the selection is all mechanical/manual.
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Unread 04-05-2015, 10:36 AM   #10
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
the bolt i circled is the one i removed and im soaking the bar that goes thru it
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Unread 04-05-2015, 10:37 AM   #11
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
here
00d60b63-7210-4b7e-af28-61f2db5a7120_zpsvc7nyv8q.jpg  
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Unread 04-05-2015, 10:38 AM   #12
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
ahh mechanical ay no wonder i couldn't find vacuum lines
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Unread 04-05-2015, 10:42 AM   #13
reydelaplaya
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1996 ZJ 
 
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Location: Cuatro Esquinas, Puerto Rico
Posts: 184
Quote:
Originally Posted by CoreyZj View Post
it looks the same and the bolt is currently out and i sprayed everything with wd40
Before we go any further, do you see any evidence that the sliding screw adjust might have been welded to the shaft by a previous owner. (Don't know why they'd do such a thing, but figured I'd ask)

Can you take a pic and post it?

Post IMG here in forum:
EDIT: NVM, I see you know how to post a pic.
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Unread 04-05-2015, 10:50 AM   #14
reydelaplaya
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1996 ZJ 
 
Join Date: Nov 2010
Location: Cuatro Esquinas, Puerto Rico
Posts: 184
Quote:
Originally Posted by CoreyZj View Post
so i loosen the screw and it still wont move freely 4d40 was used on it even tried to genitally hit it with a hammer it still wont move
There might be the problem. Few things like getting sprayed with wd40 and hit in the genitals with a hammer.

Sorry, couldn't restist. LOL

Just let the wd40 sink in for a while, and just keep rewetting it. It'll loosen up if it's not welded. Try freeing it with the selector lever.
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Unread 04-05-2015, 10:59 AM   #15
CoreyZj
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1993 ZJ 
 
Join Date: Apr 2015
Location: Sterling Heights, MI
Posts: 17
haha stupid auto correct didnt notice that but i got the bolt out that wasnt a problem the problem is the bar that the bolt was on wont move for adjustment here is a few pics.
3.jpg   2.jpg   1.jpg  
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