A while ago I put up a post about how my Jeep won't shift in to 4high or 4low. There is no grinding or anything. Shifting down into 4high, it just feels like the stick hits a metal gate and stops. It will slide over, and also slides down towards 4low (with some resistance, but I think this resistance is just the rubber boot) but no grinding and no 4x4.
It was suggested to me to check out the vaccum lines, which I have done as best I can. Everything seems to be tight and connected at the front, but as I follow the lines back towards the transfer case, I noticed there is a 2 pronged plug/connector, with male and female components, that have come apart. I'm not sure if this is electrical or vacuum hoses, but I don't imagine they are supposed to be unconnected.

This thing is extremely difficult to reach, with my exhaust and such being in the way, but after about 15 minutes I managed to get them together. I started up the jeep and went for a drive to test it out, but still no 4x4. I went back underneath and noticed that the plug was disconnected again. Apparently whatever device used to hold it together is not working anymore.

Can anyone help me fix this, or even tell me if this is going to solve my problem? The dealership told me that there was definitely a problem with my transfer case, probably a stripped gear, but the responses here suggested it may be a simpler problem. Any help whatsoever would be much appreciated, I really don't want to take it to the dealer to have them bend me over.

thx again,

Simon.

a stripped gear in your t-case? i sure hope not...

I don't see what a connection coming undone has to do with the gears inside. Where exactly is this fitting that is coming disconnected?

To shift into 4lo, you need to be in neutral. When you shift it into 4lo, does the gear reduction work? I am assuming yes. Your transfer case is probably fine. Put it in 4 and see if the front driveshaft is being turned. My guess is yes. You should connect the vacuum lines, see if you can keep them together with a zip tie. Most likely, your 4x4 works fine, just your axle is disconnected. Connect the vacuum line and see if 4x4 works. You may also want to get rid of the vacuum disco, and get a manual.

This fitting is towards the front end of the transfer case, above the exhaust (passenger side). The plug is fairly small, a little wider than my thumb and flatter. So this problem could cause the jeep to not shift into 4x4? I sure hope it is only a vacuum problem and not internal t-case. I can't afford it.

atlas II will fix it:flipoff2:

ok I didn't read your entire thread.. but here's the first to check..

Assuming a wrangler with an np231j

1) if you can't shift it in to 4lo/4hi.. it ain't a vacuum problem..it's in the tcase or a problem with the linkage.

2) if you can shift it have someone watch the front driveline, or pull both, take the tranny out of gear and put the tcase in to 4lo. both yokes on the tcase should be locked together, same as 4 hi.

3) if 1 & 2 check out ok.. then it is vacuum and the disconnect on the front of the axle isn't engaging disengaging.
a) pull the vacuum line off at that axle.. you should feel vacuumm with the engine running. if not go to step b
b) check the vacuum line at the tcase... actually a 4 prong plug.. pull that off the switch on the tcase and confirm vacuum there too (engine running again) if vacuum go to step d, otherwise step c
c) follow the vacuum line up the firewall, it plugs in next to the battery, this is where its vacuum comes from.. make sure you have vacuum there.
d) plug vacuum harness on to plug.. which is keyed.. make sure you put it in the right way. if 4wd light on dash still doesn't come on (assuming the lightbulb isn't burnt out) then proceed to step e
e) pull the disco assembly off axle... have someone shift the tcase through it's cycle with the engine running... the fork should move. if not AND you have vacuum at the harness that plugs in to it your 4wd vacuum switch at the tcase is suspect or the plug got plugged in to the tcase switch keyed wrong. (assuming your vacuum lines are in ok condition) if it moves then it is working and the 4wd sensor may be broken, or the lightbulb burnt out.

hope that helps some... I can't type anymore for now.... I sure hope someone saves this. :D

no......it doesn't seem to want to go into 4high or 4low. Neither nor.

ok.. so your tcase selector moves. and yes there is a metal gate you hit when you pull down to 4hi. the tcase selection pattern is:

|2WD
|4HI
----
|Neutral
|4Lo

I need to ask now...

WHAT IS YOUR TEST THAT YOU ARE PERFORMING THAT LETS YOU KNOW ITS NOT IN 4WD?

Originally posted by twaldher
ok.. so your tcase selector moves. and yes there is a metal gate you hit when you pull down to 4hi. the tcase selection pattern is:

|2WD
|4HI
----
|Neutral
|4Lo

I need to ask now...

WHAT IS YOUR TEST THAT YOU ARE PERFORMING THAT LETS YOU KNOW ITS NOT IN 4WD?

The fact that the stick doesn't STAY in those positions. It will move to them.....but just slides back out.....there is no feeling of any shift occuring, and the fact that only my rear wheels spin on the snow would also suggest to me that all 4 are not turning. The dash light doesn't come on either

Originally posted by SimonYJ


The fact that the stick doesn't STAY in those positions. It will move to them.....but just slides back out.....there is no feeling of any shift occuring, and the fact that only my rear wheels spin on the snow would also suggest to me that all 4 are not turning. The dash light doesn't come on either

hmm... ok.. now that is actually usefull information. Your problem is NOT a vacuum problem. the vacuum components on a YJ have nothing to do with the ability to shift the tcase lever in to a position and have it stay.

A) Inspect your shift linkage. Make sure it is actually hooked up at the little lever on the side of the tcase just ahead and below of that vacuum switch. The lever on the tcase is will look kinda like a 1/4"x1.5" flat bar of steel, with a 3/8" hole in the end if the linkage isn't hooked up to it. all you have to do is find the linkage rod, that pops in to that flat bar and should take a pair of pliers to squeeze it on. if it slides in and out easily than it is worn.. and a pair of zip ties will work to hold it on for the short term.

Before I even go in to the next possibility after shift linkage... did 4WD work before... did it work then not work after someone worked on it?

Do you have a body lify? If so you might just need to adjust your linkage for the new angles.

Odds are thats not it though, a few more questions to narrow it down a bit:

- does it engage then disengage quickly, or never at all?
- does it jerk, or make any noises when you attempt to go fwd?

It definitely sounds internal, just need to narrow it down...

Nope, no body lift. It does not engage at all. It feels as though the stick itself is not connected to anything in the xfer case at all. The stick will go through the motions, without any feeling of engaging anything. There is no jerk, no grinding, no noise of any sort.

Sounds like it could be something as easy as your shift fork. It could just be off of the "pegs" that connect to the piece that slides the gear over the 4wd gear and the planatery setup.

B/c there is no noise that leads me to believe that there are no broken gears or bad bearings. Sounds pretty simple. The next thing you need to do is take off the back cover and take a look.

E-mail me if you need more help, I've taken one too many 231's apart.

P&T - I just emailed you

on my YJ, my linkage is adjustable. If the screw that attaches the shift lever to the linkage has come loose then you will be able to move the lever (stick) without actually moving the T-case mechanism... yours might be set up in a similar manner...

Good Luck.

ok, I think I almost have it figured out......the lever that attaches to the shifter/gear selector is definitely not attached to the linkage. there is a rubber grommet on the passenger side of the linkage lever that looks like it is supposed to slide into the shift lever, but it is not in there. Are there any screws/nuts that should be in place, or does this just squeeze back in with some force??

If your talking about that rubber grommet that on the rod that looks like it should squeeze in to the hole on the shifter arm that his bolted to the tcase you are correct (you mean the drivers side right?)

Line it up with the hole and take a pair of big pliers to make it easier to squeeze in.. should be a pretty snug fit.

yes, the assembly is on the drivers side of the tcase, but the grommet is on the passenger side of the linkage rod ; )

I'm on my way out with a big pair of pliers ; )

Originally posted by SimonYJ
yes, the assembly is on the drivers side of the tcase, but the grommet is on the passenger side of the linkage rod ; )

I'm on my way out with a big pair of pliers ; )

:rolleyes: :rolleyes:

k, exactly how BIG do these pliers have to be??? That grommet does NOT want to go into that opening.

Originally posted by SimonYJ
k, exactly how BIG do these pliers have to be??? That grommet does NOT want to go into that opening.

It should start to fit in.. then some 10" pliers or channel locks will do the trick.

Jaw on pliers need to open up to around 1.5" or so. (If I remember right) It's a pretty snug fit.

This would be easier if you had a camera ya know. ;)

I know, it would be SO much easier!

Unfortunately, I don't have any pliers that big....or my hands just aren't strong enough......dammit:mad:

I picked up a pair of 12" channel locks, and still could not squeeze that little b!tch through. I had me and a a friend of mine both squeezing the hell out of the pliers, and it would not pop through. I even sprayed some wd-40 type lubricant on the grommet beforehand.

I'm returning the pliers tomorrow and buying the biggest damn pair that they have in the store. If that doesn't work I'm going to set my jeep on fire.

Prob didn't think about it, but speaking of fire, heat that bitch up. It might fawk it up a bit if you get it too hot, been there done that...

yeah....I was actually contemplating crawling under there with a propane torch........the -20 weather outside probably makes the task tougher than normal.......kinda paranoid about torching the salty whore though

ok, so how 'bout that torch idea.......it's not sounding so bad anymore.....-10 right now and I still haven't fixed this thing. I actually have some time right now, so I should give it a shot.

IT WORKED!!

Just a little tip for next time, don't use your hands. Physics is your friend, so get some big ole pliers and a large C clamp. Use the clamp to pull the handles of the pliers together. You will exert way more force this way than you ever could bare handed. That tip has saved my bacon on more than one occassion.