96 zj 492 tcase not working in 4lo - JeepForum.com
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post #1 of 6 Old 10-22-2021, 01:40 AM Thread Starter
cheapwheelr
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96 zj 492 tcase not working in 4lo

hello y’all, so i’ve been browsing the forums but can’t seem to come a general consensus on what i should be looking for. basically, i bought a project wheeler. a 96 zj. it’s got the 492 tc.

now, maybe it’s me doing something wrong but it does not want to work in 4lo. 4high works flawlessly, but whenever i try to go into 4lo, as soon as i put it in drive it slips out and just grinds until i shift the trans in Neutral and slam the tcase in 4high.

i have tried shifting while rolling i.e. rolling slowly and slipping trans in N and shifting to 4lo, didn’t work. tried while stopped in N, no dice. attempted to adjust linkage, and shift into 4lo with car off and didn’t work, attempted with adjusted linkage and car in N while stopped, nope. tried manually shifting from the linkage with the adjustment bolt completely removed, still nada.

on one attempt, car off, i put trans in N, tc in 4lo, trans back in park, started car and as soon as i shifted in reverse with foot on brake, the car jerked back and started revving (i shut it off in a split second when it started revving).

at this point i’m guessing it’s either my own error, or something inside the tc is not right.

i’m new to the jeep 4x4 system so this is pretty foreign to me.

any help on what i should look at/for or do is greatly appreciated.

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post #2 of 6 Old 10-22-2021, 01:44 AM Thread Starter
cheapwheelr
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i am not sure why my post is being weird, all my apostrophes show “ €™️” not sure why. sorry for the confusion.
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post #3 of 6 Old 10-22-2021, 01:49 AM Thread Starter
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also total screw up on my part 249 not 492 tcase.
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post #4 of 6 Old 10-22-2021, 07:13 AM
RefinedSouthern
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96 zj 492 tcase not working in 4lo

249s are notorious for having trouble if they have a good bit of mileage on them. Generally speaking, the viscous coupler ends up going out which will create some oddities.

When you shift into 4 low its suppose to be full engagement for both front and rear drive shafts where as when youre in 4 hi it will be using the viscous coupler to apply torque when the coupler slips.

All of that said, it sounds like youre not getting good engagement into the 4lo position which is why you hear grinding. I would say try pulling harder but not to hard. I have driven several vehicles with all kinds of transfer cases and can tell you that sometimes you just need to be firm with the shift. Just be careful not to break anything thats not already broken.

Another issue might be that the shift fork could be broken or missing the tabs which would make the shift harder as well.

Last resort, rebuild it or swap it for a 242 or 231. Personally I prefer the 231 and thats the route I ended up going with my Zj.

Best of luck with the new project.

96 ZJ, work in progress
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post #5 of 6 Old 10-22-2021, 09:21 AM
kg6mov
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It sounds like you’re just not getting into 4lo. That’s not uncommon when the case has basically lived in 4hi its whole life.

Try pulling through the grind (rolling barely, transmission in neutral), I’d wager it pops into 4lo and gets easier after that.

The 249 does have a wear item in it (VC) but that only affects the 4hi operation. The shift mechanism is identical to the 231.
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post #6 of 6 Old 10-22-2021, 12:53 PM
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I bought my 5.9 when it was 12 years old and odometer was reading 90k miles. I'm about 100% sure 4 lo had never been used. The first couple wheeling trips TC was constantly kicking out of 4lo. It never happened later on, so it was just lack of use.

As has been mentioned, when selecting 4lo or going back to AWD main tranny needs to be in neutral, and preferably roll in a straight line @ 2-3mph and pull firmly in one continuous motion all the way into the mode.

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