Intermittent 4WD Problem

[Pinkyman]

So ive noticed my 98 XJ has done this since i got it a month ago, but since this is a primary winter/hunting/ice fishing/off road rig, i really need to try to get it sorted.

My issue is this: Once in a while, my 4WD will engage perfectly, either while at a slow speed, or stopped (by engage, i mean the light illuminates, and i can feel the system working). Ive been noticing that the majority of the time, I can physically move the lever from 2Hi to 4Hi, and the "part time" light on the dash does not illuminate, and the 4WD system does not seem to engage. It will do the same whether moving at slow speeds, stopped in neutral, or stopped in park.

Any ideas? Could the linkage cause this?

[NW99XJ]

On the late model transfer cases, there is a switch that sits in the top of the case that tells the rest of the system that the rig is in 4wd.... illuminating indicators in the dash, etc....
The mechanical aspect of the transfer case should not be affected by this, so shifting it into 4hi or 4lo SHOULD still produce a mechanical change in the drivetrain. If it is not, then I would think you may be due for an adjustment of the linkage.
The "Z-Gate" shift mechanism that is the XJ's means of shifting the T-case is not what I would call a perfect design.
http://i519.photobucket.com/albums/u354/khinks01-02/TCLinkage-Page-1.jpg

the "Adjusting Trunion" is the part that will require adjustment if it;s not engaging properly.
This will require two people (to make things easy on yourself)
Having someone sit inside the rig, have them shift the t-case.
Watch the direction the lever turn on the side of the transfer case, you'll be manually moving this yourself here in a min.
Loosen the "trunion bolt" ....this will allow the linkage to slide thru the adjuster.
Manually engage the transfer case into 4 lo with a wrench on the side of the case where the lever actuates the selector. Then have the person sitting inside pull the lever all the way to 4lo. Tighten the trunion thingy, and then try the shifter thru all its positions.
You may have to do this a couple times to find that ideal "sweet spot."
Take it for a spin and see how it does.

Here is a bad video of the process I found on youtube:
https://youtu.be/BHp2hdvZ4oY

Good luck.
hope this helps.

[nickyg]

I had a similar problem and that's what fixed it for me. Have some PB blaster on hand.

[Pinkyman]

You guys kick ass. Ill have to try the linkeage adjustment when i get home and see what happens. Thwn maybe ill go play in the woods to make sure it works :D

[abebehrmann]

You guys kick ass. Ill have to try the linkeage adjustment when i get home and see what happens. Thwn maybe ill go play in the woods to make sure it works :D

Good idea, there is obviously no other way to test it! :patriot:

[slvmart]

Here is what I used to do a Transfer Case shifter conversion, after I installed about a 3 1/2" lift. The stock shifter was misalignment due to the partial mounting of the mechanism to the body. Now the linkage is simply attached to the transfer case and is pretty rock solid. The only other modification, beyond these parts is that a cam out of flat stock will have to be fabricated. I believe I used the attachment point that was used on the stock shift mechanism. (It's been a while) The biggest trick is figuring out the length of 3/8" rod stock that is required in 2 locations.

http://www.mcmaster.com/mv1445545928/#60645k441/=zkhnv2[
http://www.mcmaster.com/#1583k14/=zkhokq[
http://www.mcmaster.com/#99086a126/=zkhp5g

I did make all the adjustments without assistance, it isn't all that difficult once you pay attention to how the shifter and the arm on the transfer case need to move.

[Pinkyman]

I think I have narrowed it down to a faulty sensor.

It works fine every time, when it's cold. As soon as it warms up, I get no indicator light. I'll have to test that theory and make sure the 4wd is still functional as soon as I find some time.