96 zj 492 tcase not working in 4lo - JeepForum.com
  • 1 Post By kg6mov
LinkBack Thread Tools
post #1 of 6 Old 10-22-2021, 01:40 AM Thread Starter
Registered User
Join Date: Oct 2021
Posts: 6
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.

cheapwheelr is offline  
Sponsored Links
post #2 of 6 Old 10-22-2021, 01:44 AM Thread Starter
Registered User
Join Date: Oct 2021
Posts: 6
i am not sure why my post is being weird, all my apostrophes show “ €™️” not sure why. sorry for the confusion.
cheapwheelr is offline  
post #3 of 6 Old 10-22-2021, 01:49 AM Thread Starter
Registered User
Join Date: Oct 2021
Posts: 6
also total screw up on my part 249 not 492 tcase.
cheapwheelr is offline  
post #4 of 6 Old 10-22-2021, 07:13 AM
Registered User
1996 ZJ 
Join Date: Feb 2020
Posts: 48
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
RefinedSouthern is offline  
post #5 of 6 Old 10-22-2021, 09:21 AM
Hears the voices
kg6mov's Avatar
1996 ZJ 
Join Date: Nov 2012
Location: Cupertino
Posts: 16,524
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.
Timo_90xj likes this.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1984 F250, 460 BB, T19, work truck/future tow pig
1987 Mercedes 300D Turbo, the diesel daily, 30mpg in style

Originally Posted by Texas ZJ1 View Post
I heard someone yell "mall crawler" from the back porch. I'll go see who said that. Be right back.
kg6mov is offline  
post #6 of 6 Old 10-22-2021, 12:53 PM
Web Wheeler
Timo_90xj's Avatar
1998 ZJ 
Join Date: Mar 2006
Location: Helsinki, Finland - on the European side of the Atlantic
Posts: 11,203
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.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
Timo_90xj is offline  

Quick Reply

Register Now

In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.

Email Address:


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome