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Unread 02-22-2009, 04:57 PM   #1
lecharbon
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2002 TJ Wrangler 
 
Join Date: Apr 2008
Location: , Republic of Texas
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Transfer Case shift linkage adjustment

When adjusting the linkage for my year of jeep are you supposed to use an 1/8 inch shim behind the shifter? Reason I ask is it is starting to pop out of 4wd.

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Unread 02-22-2009, 06:07 PM   #2
TheBoogieman
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No shim.
Straight from the FSM:

SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position. (make sure your shifter is fully in the 4L position)
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig.
87).
(4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully
engaged in 4L position. (you can do this under the vehicle at the transfer case)
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle

Basically, you are just ensuring that the position you put the lever inside the vehicle is the same position that the tcase lever is in and then tightening the locking bolt.
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Unread 02-22-2009, 06:07 PM   #3
Ged4th
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Quote:
Originally Posted by lecharbon View Post
When adjusting the linkage for my year of jeep are you supposed to use an 1/8 inch shim behind the shifter? Reason I ask is it is starting to pop out of 4wd.
I too am having a similar problem with my 99. I have a total of 7 inches of lift and just recently it has started popping out of 4 low. Not a good thing when climbing a rocky slope. Anybody with any suggestions on this matter?
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Unread 02-22-2009, 06:10 PM   #4
TheBoogieman
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When I had a BL I had to notch the plate for the shift linkage to get it to stay in 4LO.

Last edited by TheBoogieman; 08-28-2009 at 08:23 AM..
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Unread 02-22-2009, 06:48 PM   #5
Ged4th
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Thanx for the info. I will certainly give it a try. Anything to keep it from popping out of 4L.
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Unread 02-22-2009, 07:16 PM   #6
wrangler2007
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Quote:
Originally Posted by Theboogieman View Post
No shim.
Straight from the FSM:

SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position. (make sure your shifter is fully in the 4L position)
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig.
87).
(4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully
engaged in 4L position. (you can do this under the vehicle at the transfer case)
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle

Basically, you are just ensuring that the position you put the lever inside the vehicle is the same position that the tcase lever is in and then tightening the locking bolt.
What site is that off of? I'd like to see the pictures lol...no lie...
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Unread 02-23-2009, 06:06 PM   #7
lecharbon
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Turned out my linkage rod is bent. I had to move it until I found 4 hi and then go under and loosen the bolt. I then moved the lever back and retightened the bolt. It now shifts and stays. imagine that. Does anyone know if the linkage bar comes off the small bushings or what?. The bar is still bent, but works.
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Unread 02-23-2009, 09:03 PM   #8
spdcat01TJ
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You can just pry the shift rods out of the bushings with a screwdriver, and them pop them back in with channel locks or pliers. My rod is bent too, I'm wondering if it's supposed to be that way.
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Unread 10-20-2009, 02:11 PM   #9
04silvrtj
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my t case locks now but front wheels don't spin and when they do you can hear them pop in and out what is that all about. do i need to get rid of t-case drop since i put in slip yoke elim kit
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Unread 02-02-2010, 02:49 PM   #10
gcrv01tj
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2001 TJ Wrangler 
 
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Location: Richmond, VA
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Quote:
Originally Posted by TheBoogieman View Post
No shim.
Straight from the FSM:

SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position. (make sure your shifter is fully in the 4L position)
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig.
87).
(4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully
engaged in 4L position. (you can do this under the vehicle at the transfer case)
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle

Basically, you are just ensuring that the position you put the lever inside the vehicle is the same position that the tcase lever is in and then tightening the locking bolt.
anybody ever do this? is there a more descriptive write up with pictures? I can't find one. My transfer case works great in 2HI and 4LO but it wont stay in 4HI if it goes in or it doesn't go in and makes grinding noises.
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Unread 02-20-2010, 07:57 PM   #11
amike_321
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Location: Rock Hill, SC
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Did mine this evening, no pictures needed. you will see what needs to be adjusted once you get under there. Read the instructions and do exactly as they say and you should do fine.
I was having a hard time getting mine all the way into 4lo without holding the transfer case shifter lever all the way back. Smooth as butter now.
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Unread 02-21-2010, 08:50 AM   #12
Niceface
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I'm getting ready to order a Novak shifter to end this battle once and for all. From everyone i've talked to that owns one...the best $150 they have ever spent.

Novak's NP / NVG Shifter Assembly for Jeeps
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Unread 02-21-2010, 10:43 AM   #13
alvinl
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Quote:
Originally Posted by wrangler2007 View Post
What site is that off of? I'd like to see the pictures lol...no lie...
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Unread 06-30-2010, 09:26 PM   #14
VecoPlan
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Quote:
Originally Posted by alvinl View Post
Like this?


Its out of the FSM. buy one for your year Jeep- best investment you'll ever make if you plan to have that Jeep a long time.
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Unread 09-24-2010, 11:42 PM   #15
Hookster
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Ya know what? Save some money. Replace the stock linkage with the stock kit, readily available thru any reputable 4WD repair shop. I have a 98 TJ with a 4 in short arm lift and a 1 in body lift and a slip yoke eliminater. I had to put in a new rear drive shaft, but didn't have to touch the front. I removed the spacers and brought the trans case back up to the frame and cut a piece out of the front to allow the front drive shaft to move down without hitting the skid plate. Rather than use the supplied linkage location bracket when I installed the body lift, I just put in a 1 in motor mount lift from JKS and repositioned the radiator. Tht gave me some more ground clearance. Unfortunately, I didn't replace the tranmission mount and it wore out, causing the tranny to move around and thats what led to the tranfer case linkage failure. Replaced with a Daystar mount and the stock linkage fix-it kit. So far, so good.
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