Stuck in 4lo, but lever moves freely

[Jim McClain]

Took a friend 4-wheeling today and had a great time. Had to shift into 4lo at one point and used that for most of the rest of the ride. Once we got back up on flat dirt, I came to a near stop and tried to move the lever to 2wd. The lever moved, but the 4lo indicator light stayed on. I noticed the tire pressure light was on, so I thought it was just spill-over light that made the 4lo light look on. It wasn't too many feet that I realized it was still in 4lo, even though the lever was all the way forward. I moved the lever and it moved very easily - prob'ly too easily - back and forth with no apparent pauses or detents in 4part time, 4full or 2wd. The only stop was the neutral bump stop where you have to move the lever to the right to go down to 4lo.

The lever almost feels like there is no linkage attached. I left the owners manual on my desk, so I couldn't trouble-shoot shifting patterns. By the time I read the section in the manual, I discovered the front tire was flat, so now I can't run any tests.

My friend is coming over tomorrow to change the tire. Maybe some of you can suggest what we look for to help with the transfer case problem.

Thanks,

Jim

 

[ltd02]

Sounds like the bushing on the cable end let loose at either the lever or the tcase. Result is the cable no longer does its job. I'd check the tcase side first if you can get under there.

For the tcase end:

MOPAR Transfer Case Shifter Bushing for NVG231 Transfer Case - Sold Individually - 68001899AA-M

 

[Jim McClain]

Sounds like the bushing on the cable end let loose at either the lever or the tcase. Result is the cable no longer does its job. I'd check the tcase side first if you can get under there.

For the tcase end:

MOPAR Transfer Case Shifter Bushing for NVG231 Transfer Case - Sold Individually - 68001899AA-M

It looks like this was exactly the problem. The linkage separated from the bushing somehow. My buddy came this morning to change the tire (I seriously smashed my ring finger trying to put the flat back on the spare carrier) and crawled under the Jeep to check the linkage. The bushing was there still and he reconnected them. The Jeep is now in 2wd.

I think I will order the part you linked to anyway. It could be the original is worn or cracked and a new bushing seems like cheap insurance.

Thanks very much for the info and link.

Jim

 

[Jim McClain]

Does anyone know... is there a retainer clip/c-clip that holds the linkage shaft in the bushing? Or does the shaft have a raised edge that compresses the inside of the bushing until it goes all the way through, then the bushing relaxes and prevents the shaft from coming out?

My friend said the bushing seemed to be intact and thought the linkage shaft had smooth sides. Viewing the image of the bushing makes me think it was designed to be compressed from the inside, making the hole slightly larger as the flared end of the shaft was pushed through.

You must be registered for see images

Maybe it's just a c-clip that holds the shaft in place. That would mean there should be a groove near the end of the linkage shaft, but I didn't want to ask my friend to get back under there to check again. I was so grateful that he changed my flat tire and managed to re-seat the linkage and get the KJ in 2wd.

I'll be taking it to the shop tomorrow, but I want to be able to help the mechanic sort out the problem, or maybe save the hoist fee and just order the right parts, if more are needed. I held off ordering the bushing until I have a clearer idea of the big picture.

Jim

 

[ltd02]

Does anyone know... is there a retainer clip/c-clip that holds the linkage shaft in the bushing? Or does the shaft have a raised edge that compresses the inside of the bushing until it goes all the way through, then the bushing relaxes and prevents the shaft from coming out?

My friend said the bushing seemed to be intact and thought the linkage shaft had smooth sides. Viewing the image of the bushing makes me think it was designed to be compressed from the inside, making the hole slightly larger as the flared end of the shaft was pushed through.

You must be registered for see images

Maybe it's just a c-clip that holds the shaft in place. That would mean there should be a groove near the end of the linkage shaft, but I didn't want to ask my friend to get back under there to check again. I was so grateful that he changed my flat tire and managed to re-seat the linkage and get the KJ in 2wd.

I'll be taking it to the shop tomorrow, but I want to be able to help the mechanic sort out the problem, or maybe save the hoist fee and just order the right parts, if more are needed. I held off ordering the bushing until I have a clearer idea of the big picture.

Jim

No retainer. My 02 with the 242 case had a raised edge in the linkage shaft that locked the bushing on. First I had to press the bushing into the cable end (not exactly an easy task) and then the assembly "snapped" onto the shaft.

 

[Jim McClain]

No retainer. My 02 with the 242 case had a raised edge in the linkage shaft that locked the bushing on. First I had to press the bushing into the cable end (not exactly an easy task) and then the assembly "snapped" onto the shaft.

Okay, that is one of the ways I described above. Good to know. Now I'm wondering if it may be the linkage shaft that needs to be replaced and not the bushing. My friend said the bushing seemed to be fine. He said the linkage shaft slipped into the bushing's hole with no resistance.

I guess the only way to know for sure is to have the mechanic look at it. If I had ramps I could prob'ly check this myself, but unfortunately, I don't. I need ramps to be able to install my new used tow hooks, so maybe I'll bite the bullet for ramps.

Thanks,

Jim

 

[Jim McClain]

Found a part called a transfer case shift shaft repair sleeve (see image). I wonder if this is what's made to fix this problem? National Redi-Sleeve at RockAuto

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[CzarKJ]

Okay, that is one of the ways I described above. Good to know. Now I'm wondering if it may be the linkage shaft that needs to be replaced and not the bushing. My friend said the bushing seemed to be fine. He said the linkage shaft slipped into the bushing's hole with no resistance.

I guess the only way to know for sure is to have the mechanic look at it. If I had ramps I could prob'ly check this myself, but unfortunately, I don't. I need ramps to be able to install my new used tow hooks, so maybe I'll bite the bullet for ramps.

Thanks,

Jim

If you want to keep yourself in good health I wouldn't suggest ramps. Can get a little dicey. By chance do you have a floor jack? Then you can use jack stands to be much safer.

 

[Jim McClain]

Nope, no floor jack. Maybe that would be the better route than ramps. I'll be sure to get jack stands too.

 

[ltd02]

Found a part called a transfer case shift shaft repair sleeve (see image). I wonder if this is what's made to fix this problem? National Redi-Sleeve at RockAuto

You must be registered for see images

Actually have no idea what that is for???

I'm trying to recall a few years ago when I changed mine but I seem to remember the bushing having a flat side that goes toward the tcase (as in the image above) and a raised end that faces away. This raised side (see below) has a smaller opening and the linkage lever had a groove that the smaller portion fit into. I remember it being quite intuitive but if this "ridge" in your bushing failed from wear or degradation then it would slide off very easily. Mine completely fell apart.

 

[ltd02]

Here's more possible fixes but I liked the original bushing route.

http://www.jeepkj.com/forum/f196/cheap-fix-transfer-case-cable-bushing-clip-47531/

 

[Jim McClain]

Here's more possible fixes but I liked the original bushing route.

http://www.jeepkj.com/forum/f196/cheap-fix-transfer-case-cable-bushing-clip-47531/

Thanks, I read that thread earlier today. I agree with you, the original would be my choice. However, if there is a way to modify parts to make them better, or to use better, purpose-built parts, I would consider those options too.

Jim

 

[ltd02]

However, if there is a way to modify parts to make them better, or to use better, purpose-built parts, I would consider those options too.

Agreed. However in this case I'm pretty sure my bushing was original and lasted about 12 years and over 150k so figured that was good enough and about all I could hope for in the OEM replacement. arty52:

 

[Jim McClain]

Took the KJ into my mechanic today. He didn't see anything amiss and the linkage seemed to be snug in the bushings. He seemed to think the problem bushing (or whatever it's called) is a white plastic clip-in type fitting. He said I might have popped it out when trying to force the lever into 2wd while driving too fast or just not doing it according to directions. He tugged on it a little and the cable and fitting were tight. The other bushing had a lot of dirt and grime around it and didn't look like it had been apart or put back together - it should have shown signs of being handled.

I mentioned some of what was discussed here in this thread and when I told him I got some of my information on an internet forum, he got kinda irritated and even condescending. That pissed me off. Although I haven't known you guys very long, I've been managing discussion forums in a variety of niche areas since 1992 and think I have developed a sense about online experts (as opposed to "experts"). I enjoy doing the research, not just about the issues I have, but on the people who offer assistance. I check their profiles and read many of their previous discussions. In matters like this, I know better than to make judgements based only on intuition, although that is what initially piques my curiosity.

So, since the owner of the shop I go to has this attitude and is dismissive about the information I try to provide (which comes from some of you), I'm wondering what I should do in the future. His mechanic employee, who did the first inspection of my Jeep when I bought it, seemed to know his way around a KJ and I know he's an avid 4-wheeler (he's building a custom 4-wheeler in his spare time). Should I ask that only he work on my KJ, or should I ask around town about any other good 4wd mechanics?

I took my Jeep into some loose dirt and changed into the various 4wd options and didn't seem to have any problems. But what about next time?

Jim

 

[CactusJacked]

I mentioned some of what was discussed here in this thread and when I told him I got some of my information on an internet forum, he got kinda irritated and even condescending.

I spose you could ask him if he dismisses the experience (not opinion) of a good number of Liberty owners here who have worked on many a nut and bolt of this vehicle and has had these parts in their hand, vs himself who has run into this case maybe once or twice (just a guess)? Probably not worth it, as it sounds like perhaps he feels his manhood has already been challenged. :happy175:

 

[HoosierJeeper]

I'd find a new shop perhaps. The guy I go to uses the forums too on occasion and it always open to ideas, lets me bring in my own parts too.