2nd Gen Non-Engine/Transmission Transfer case stuck in 4WD

[TurboSandman]

Help; I am stuck in 4WD and I can't get it out!



I can easily shift from 4-HI to neutral and can get into 4-LO with some cussin' but my vocabulary is too limited to get back into 2-HI. I had a SB Con OFE 13'' conversion clutch installed about 100 miles ago and this is the first time I have shifted into 4WD since then. The clutch is nearly seated and doesn't engage as close to the floor as when first installed, but could this be part of the problem or is this more likely a result of removal and replacement of the transfer case?



Any thoughts?

 

[Extreme1]

You just need to expand your vocabulary!



Have you tried it with the engine off? Stopped or moving slowly? The T-case R & R shouldn't have affected the adjustment, just unbolt the lever and the handle bracket.



Is the T-case full of lube? Worn forks might not allow it to shift right.



If it shifts OK with the engine off, it's the clutch adjustment.

 

[bighammer]

Are ypu sure it is really in 4wd or is the light just on? Maybe the front axle is not unlocking and keeping it lit up.



I guess if you jack a front corner and try to spin the wheel, it may tell you something.

 

[TurboSandman]

I think it really is in 4WD as the shifter will go directly to the right and back into neutral, but will not go any farther forward from the 4WD position. I have tried it with engine off and running, moving and at a standstill, with no success.



I will check lube level and inspect for anything obviously jammed in the linkage, like a loose bolt, etc. I suppose the next step will be to tear into the linkage and see what's what.



Thanks for the responses.

 

[Joe G.]

Have you checked the adjustment on the transfer case shift rod? It's kind of touchy so if it's not quite right it will do what your's is doing. I would loosen the lock screw on the rod and see if it will shift properly if you do it by hand. It's kind of stiff so when you do try it you should have all four wheels off the ground.

 

[time1]

Had a similar problem with a 99 4x4. It was a vacuum leak going to the 4x4 connect - disconnect sleeve on the axel. It must have had enough vacuum to get 4 wheel drive engaged but not enough to disengage. My leak was found up on the firewall where a vacuum hose had a split end. It might be worth a look because it is very easy to fix.

 

[emjay]

The 4WD indicator only means that the axle disconnect is engaged. Is the problem that you can't move the T/C shift lever to 2WD or is the 4WD indicator lit all the time?

 

[Big Best]

trs case

it happened to me . it is the vacumn gismo on front axel . or in one of the vac. lines

 

[TurboSandman]

I guess it could be a vacuum line, but would that prevent me from shifting it into 2-Hi? The T/C shifts from 4-Hi to Neutral easily, and from Neutral to 2-Lo with some effort (just like always), but 2-Hi; no can do.



I will check out the linkage like Joe G. suggested and also explore the vacuum situation as I would like to BOMB it with a 2WD Low kit eventually. I sort of busted the 'ol piggy bank on the clutch or I would take Piers up on his 2 wheel low sale price.



I guess I'll drive the kid's car (VW New Beetle with Turbo Diesel 5-Speed) until I have time to crawl around under the truck. The VW is actually a pretty good entry level diesel with good performance and great mileage.



Thanks for all your help; I'll post again when I (or someone intelligent) figures this out.

 

[Joe G.]

I don't think it is the vacuum thing. That would not prevent the lever from moving to the 2 HI position. A vacuum problem might prevent it from disengaging the front axle once the lever had moved. I had the same trouble after removing the t-case once. The hi-tec adjustment is just a set screw in the t-case lever holding the shift rod in place. If it slips a little or is tightened in the wrong place it can prevent moveing the shift lever inside the cab. I set mine by loosening the set screw and moving the t-case lever to the 2 HI position. I had to hit it with a hammer because it's pretty stiff. Then I moved the lever in the truck to that position. Even after I retightened the set screw I had to mess with it a little to get it just right. Once you get under there you will see what I mean.



The movement from left to right of the shift lever is pretty hi-tec too. It's just a dog leg in the bracket that fastens the shift lever to the transmission. The actual shift lever on the t-case is just a back and forth movement with "notches" it stops in.



While you are under there you might want to check the vacuum connection block on top of the t-case. It has one funny corner to prevent it from being installed wrong. A ham handed "technician" at Dodge could force it on wrong. A little Sil-Glide (get it at NAPA) helps with that aggravating thing.



After those guys worked on it I would check the whole thing anyway. The levers and all vacuum lines and connections. Obviously they test drove it before they returned it to you.

 

[Mingoglia]

Sorry, this isn't any help but. . .



"I can easily shift from 4-HI to neutral and can get into 4-LO with some cussin' but my vocabulary is too limited to get back into 2-HI"



. . . is probably the funniest thing I've ever heard.

 

[TurboSandman]

Joe G. , I followed your advice and was able to get the transfer case into 4-Hi. I can now shift into all positions, even with my limited vocabulary (thanks, Mingoglia).



So, I fired her up to see whats what and now the 4WD light comes on in 2-Hi and GOES OUT in 4-Hi and 4-Lo.



I am thinking vacuum leak along with the now fixed linkage maladjustment (or maybe it is a maladjusted driver). I am going to take a hot cup of coffee and the newspaper and sit in my thinking room until I sort this one out. Yes dear, I will turn the fan on.

 

[Joe G.]

The light business sounds like the vacuum tube connection block on top of the transfer case is on wrong.

 

[TurboSandman]

Joe G. ; You the man!



You are correct sir; unfortunately one of the tubes on the vacuum switch is broken off and I am unable to get a vacuum seal.



The good news is that I now have 2WD-Lo.



The bad news is that I also have two flavors of 2WD-Hi and no flavors of 4 wheel anything.



I have a call in to Blumenthal's for parts recommendations, but while I have all you experts out there, does anyone have any experience with this?

 

[Whitmore]

Sounds as if you crossed your vacumn lines when you spliced for your 2wd low kit ? I installed the Bob V kit and it came with excellent detailed instros, Bob says you can simply reverse the vacumn lines at the switch if need be.



cheers, Kevin

 

[TurboSandman]

Whitmore;



I do not have a 2WD Low kit; I was just attempting a minor funny. One of the nipples on the vacuum switch atop the transfer case is missing after repair (sabotage?) by a local shop.



I have, in effect, a 2WD vehicle with a transfer case as the loss of vacuum prevents the front axle from engaging. If I rotate the vacuum connector on top of the transfer case, I can achieve several interesting effects including 2WD with a locked front axle and 4WD Hi and Lo with an unlocked axle. Pretty cool, huh?



I am rapidly tiring of these special effects and would like to restore the vehicle to its prior state of functionality. Apparently this is possible by replacing the vacuum switch.



I just wonder if anyone here has had similar adventures with their transfer case and if so, how they recovered from them. Maybe someone knows of a support group nearby.

 

[bighammer]

There is a kit to eliminate the vacuum shifter and use a cable instead. It would give you all the special effects from the comfort of your cab.

 

[TurboSandman]

Incredible!



I called the dealer and they have the switch in stock! Four of them, in fact and they only cost $22. 00; what an easy fix.



I know, I know, its not installed yet, but it just looks so good. Consider this case closed. I'll post the part number in case anyone is interested.



Thanks for all your help.

 

[TurboSandman]

The part number for the NV 241 transfer case (standard duty) vacuum switch is 53001101. It installed with a minimum of effort and restored full function.



Thanks