Transfer Case Pops out of 4Low moving forward

Gunmetal6033 · 04-30-2009, 07:23 PM

I have a 1999 TJ stock, When I use the transfer case in 4Hi all is good When I go into 4Lo it will pop out as soon as the jeep moves forward. I can move in reverse it will stay in 4Lo. Have searched and read all posts.....I think maybe it needs adjustments. Just want to get some ideas from you guys and girls.

**Jerry Bransford** · 04-30-2009, 07:34 PM

It's likely nothing more than your transfer case's external shift linkage has simply slipped out of adjustment a tad so it's not pulling the transfer case all the way into 4Lo. It's pretty common and no big deal.

With someone sitting in the driver's seat to pull the lever back when you tell them to, crawl underneath until you can see the linkage. Then have them pull it into 4Lo so you can see how it works. Then you'll see a bolt in a bracket on the linkage with a 1/2" head on it that if you loosen the bolt, you can move the linkage so it grabs the shift lever a little more to make sure it is pulling it all the way into 4Lo. Then tighten the snot out of the bolt so it won't slip again. It's easier to do than described, I hope this helped. And a big welcome to JF!

**RnEmOvr** · 04-30-2009, 07:35 PM

yes you need to do te adjument, also check your trans mount as well, this could be causing the popping out in forward but not reverse

**goldrush** · 04-30-2009, 07:57 PM

Quote:

Originally Posted by Jerry Bransford

It's likely nothing more than your transfer case's external shift linkage has simply slipped out of adjustment a tad so it's not pulling the transfer case all the way into 4Lo. It's pretty common and no big deal.

With someone sitting in the driver's seat to pull the lever back when you tell them to, crawl underneath until you can see the linkage. Then have them pull it into 4Lo so you can see how it works. Then you'll see a bolt in a bracket on the linkage with a 1/2" head on it that if you loosen the bolt, you can move the linkage so it grabs the shift lever a little more to make sure it is pulling it all the way into 4Lo. Then tighten the snot out of the bolt so it won't slip again. It's easier to do than described, I hope this helped. And a big welcome to JF!

Here is a picture of the bolt Jerry is talking about

Edit by JB: Good pic, thanks... I added the little red circle around the bolt.

**goldrush** · 04-30-2009, 08:18 PM

thanks Jerry
Hey you still the only conservative in california? I'm going to get you to move east some day

Gunmetal6033 · 05-01-2009, 04:44 PM

Thanks for al the info. I adjusted the linkage as much as possible. Best i can do is get it so slight pressure on the shifter will keep it in 4Lo but if i release the pressure it will still pop out of 4Lo. Any more Ideas?

**goldrush** · 05-01-2009, 06:26 PM

is your jeep lifted? has the TC been lowered, if so a linkage reposition plate should have been added again see pictures. the bar from the TC to the linkage should be stright across not at any angle.

Gunmetal6033 · 05-01-2009, 06:34 PM

No Jeep has no lift as of yet. I have a 1" Body lift and 1" motor mount lift to install but presently have no place to work on it. Also have a Novak old syle shifter to install.

Gunmetal6033 · 06-16-2009, 10:43 PM

Have tried and tried to adjust. still can't get it to stay in for low. Following the directions in the manual. as soon as I loosen the adjuster bolt the transfer case will pop out of 4low I can shift it back into 4low manually but as soon as I release my the pressure it will pop out of 4low. Any more Ideas?
Thanks

**mudb8** · 06-17-2009, 01:36 AM

loosen the bolt, pull the lever into 4low, push the t-case lever into 4low by hand, it'll click and stay then tighten the bolt... you can do all this from under the vehicle.

if it won't stay in the 4low position clicking it in by hand without the linkage connected, you have another problem. also chec to be sure the 9/16" (14mm) lock nut is tight on the t-case lever shaft so it's not floating around, it's located just above the front output drive yoke

eric411420 · 07-05-2009, 06:59 PM

Any more on this? My 94 YJ is doing the same thing and adjusting it didn't help. I haven't tried to adjust it again since installing new poly engine and trans mounts though. I'll give that a shot but if there is more to this story, I'd love to hear it just in case my problem persists. Thanks!

(BTW, does this even apply to my YJ? 4.0?)

eric411420 · 07-05-2009, 07:06 PM

I just thought of something else, when I bought my Jeep, one of the first things I did was change all the fluids. I'll have to look in to it but I think that I may have put a synthetic or syn blend fluid in it. I know that I used what it calls for but I am not sure about whether or not I went with a synthetic version of what it calls for. Could this create a problem with it popping out of 4 low?

**Jerry Bransford** · 07-05-2009, 07:17 PM

The transfer case isn't fussy at all about the type of ATF it gets so long as it's good quality. It's happy with non-synthetic, synthetic, or a mixture of the two.

eric411420 · 07-07-2009, 03:31 AM

Thanks, that's good to know. It's also what I was hoping to hear! I'll post on here when I get under it and try again to adjust the linkage. It's been a little warm here in Phoenix and I haven't felt motivated for the last few days.

Maybe tomorrow...

Gunmetal6033 · 07-07-2009, 04:48 AM

I figured out mine finally last night. My transmission Mout was bad Replaced it 4l0w works like a charm. No more poping out.