No 2WD after SYE install

[mattjeep2003]

First off... i am noob mechanic. I have owned a YJ for 20 years... but have never did anything to it but drive it and change the oil, and weld the frame...things a tank mostly.

Now the TJ problem..

Well, there are a couple threads about this... I think this one: https://wranglertjforum.com/threads/no-2wd-after-4-lift-with-sye.55119/
Is my problem... But since the OP has been afk for a couple years.. i dont really wanna Necro the thing...

So, just installed a Teraflex SYE and Tom woods Drive shaft on my 2003 TJ. (manual, 4 cylinder... basically stock but has a 3 inch lift)

After reassembly I cant move the shift lever into 2H. (same problem as noted thread) I have 4H ,neutral, and 4L (4L is where it is during install after all).

I have taken off the the SYE shaft housing and put it back on 4 times... problem persists (and i am running out of RTV.. ha).. when the SYE Shaft Housing is off, i can move it into all gears. although, i have to do it slow and push the Oil pump back into place as the shaft moves, as it it seems the shaft seems to slide through it...

I have noticed that the shaft and oil pump can hang a bit while installing (I am doing it while transfer case is still on the Jeep) I have tried holding it in place, and keeping upward pressure on shaft while installing, wiggling as mentioned in above thread... nothing seems to work... I am running out of ideas and patience...

Wondering if i bunked something up on the internals, anyway to know without pulling it all apart? anyway to know the oil pump is in correct place for SYE shaft housing to go back on? Any other ideas? I can post pics... but not sure what would matter.

 

[macleanflood]

I didn't get my oil pump seated right and it took a couple tries to get it together. Similar shifting issues.

-Mac

 

[MountaineerTom]

I remember there being info in the instructions of my Advance Adapters SYE saying to make sure the Shift Rail only stuck out 1 inch. If it's more, you'd need to trim it down. I don't know if the Teraflex kit is like that or not, but maybe and area to look into in their instructions. Not sure it would cause your issue though. Maybe just keeping the tail housing from seating properly.

 

[mattjeep2003]

I didn't get my oil pump seated right and it took a couple tries to get it together. Similar shifting issues.

-Mac

is there a way to tell if it is seated right? never seems to stay put for me... unless i am applying pressure to it. could i be a spline off on it or something? like it is twisted 1 degree off and causing issues?

 

[mattjeep2003]

I remember there being info in the instructions of my Advance Adapters SYE saying to make sure the Shift Rail only stuck out 1 inch. If it's more, you'd need to trim it down. I don't know if the Teraflex kit is like that or not, but maybe and area to look into in their instructions. Not sure it would cause your issue though. Maybe just keeping the tail housing from seating properly.

View attachment 466485

Yeah, I read about that... I will have to check tomorrow just for checking.. but the install manual on the Terraflex doesnt mention having to do that on the 231 transfer case: https://teraflex.com/amfile/file/download/file/608/product/23140/

 

[mattjeep2003]

I didn't get my oil pump seated right and it took a couple tries to get it together. Similar shifting issues.

-Mac

anything special you did to verify it was seated correctly? or did you just keep doing it over until it worked?

 

[MountaineerTom]

Yeah, I read about that... I will have to check tomorrow just for checking.. but the install manual on the Terraflex doesnt mention having to do that on the 231 transfer case: https://teraflex.com/amfile/file/download/file/608/product/23140/

It looks like it's on page 5, step 17, but it talks about measuring the whole rod. It's likely not your problem, but I guess you could measure how deep the recess is in your tail housing and the measure how much the shaft sticks out of the case housing to be sure.

 

[macleanflood]

anything special you did to verify it was seated correctly? or did you just keep doing it over until it worked?

Three times and I finally was able to wiggle and jiggle it into working.

-Mac

 

[OldBuzzard]

Did you disconnect the main shift lever and try to just shift the short lever on the TC with pliers (turning the yoke a little)? If that gets you into every gear, then it's your linkage causing the problem.

 

[mattjeep2003]

Did you disconnect the main shift lever and try to just shift the short lever on the TC with pliers (turning the yoke a little)? If that gets you into every gear, then it's your linkage causing the problem.

No, but why would the linkage be the issue if it worked before the SYE install, and if it works with the SYE housing off? not being snarky.. real question.

 

[mattjeep2003]

Three times and I finally was able to wiggle and jiggle it into working.

-Mac

Thanks mac. thats what i feared. with my luck it will take 20 times then.... if thats the problem

 

[macleanflood]

Thanks mac. thats what i feared. with my luck it will take 20 times then.... if thats the problem

I finally stopped using RTV until I figured it out and got it working...then took it apart again, applied some Right Stuff and sealed it up.

Happy to do a video call or something if I can help.

-Mac

 

[mattjeep2003]

It looks like it's on page 5, step 17, but it talks about measuring the whole rod. It's likely not your problem, but I guess you could measure how deep the recess is in your tail housing and the measure how much the shaft sticks out of the case housing to be sure.

yeah, i saw that... after i replied... The 231 J model is supposed to have the correct length. (which is what I have...) If I decide i need to split the case again to get this working.. I am definitely going to measure.

 

[mattjeep2003]

I finally stopped using RTV until I figured it out and got it working...then took it apart again, applied some Right Stuff and sealed it up.

Happy to do a video call or something if I can help.

-Mac

I might take you up on that. ill have at it again tomorrow without RTV.. didnt think about doing that... as i just wanted it done. also worried that i will get it right... then it wont work the next time.

 

[OldBuzzard]

No, but why would the linkage be the issue if it worked before the SYE install, and if it works with the SYE housing off? not being snarky.. real question.

The linkage shouldn't be the problem. I was just trying to eliminate anything else it could be. And the linkage is somewhat famous for working fine, right up until it doesn't.

Did you remove/reinstall the shift fork and/or the mode ring? If so, did you see this discussion about how those go back in?
Odd Behavior After Transmission and Transfer Case Rebuild

 

[P man]

I remember there being info in the instructions of my Advance Adapters SYE saying to make sure the Shift Rail only stuck out 1 inch. If it's more, you'd need to trim it down. I don't know if the Teraflex kit is like that or not, but maybe and area to look into in their instructions. Not sure it would cause your issue though. Maybe just keeping the tail housing from seating properly.

View attachment 466485

I think this is only for certain yj models not tjs but it wouldn't hurt to double check the instructions like you said.

 

[mattjeep2003]

The linkage shouldn't be the problem. I was just trying to eliminate anything else it could be. And the linkage is somewhat famous for working fine, right up until it doesn't.

Did you remove/reinstall the shift fork and/or the mode ring? If so, did you see this discussion about how those go back in?
Odd Behavior After Transmission and Transfer Case Rebuild

i did remove and reinstall both. I believe i installed it correctly... based upon that thread ( I didnt see the thread before, but i took photos of what it looked like before i removed it... and made everything look the same.) unfortunately my dumbass didn't take photos when i put it back together though... so I am not ruling that out as a possibility. especially if this can cause the problem.

 

[mattjeep2003]

i did remove and reinstall both. I believe i installed it correctly... based upon that thread ( I didnt see the thread before, but i took photos of what it looked like before i removed it... and made everything look the same.) unfortunately my dumbass didn't take photos when i put it back together though... so I am not ruling that out as a possibility. especially if this can cause the problem.

Well, glad i finally broke down and decided to split the case again. my mode ring was in with long side facing the short side of the stick... IE... in the wrong direction. here is to hoping that is the only thing i did wrong. Now Back to reassembly.

 

[mattjeep2003]

Well, glad i finally broke down and decided to split the case again. my mode ring was in with long side facing the short side of the stick... IE... in the wrong direction. here is to hoping that is the only thing i did wrong. Now Back to reassembly.

That was the culprit... everything works as it should. Except for the fact I tore the Gasket on the Speedometer assembly. So, I cant finish till i pick one up tomorrow. But otherwise. Good to go. I appreciate everyones ideas and support. I might have figured it out on my own...eventually... but ya'll keep me motivated and looking at different things. Thanks!

 

[MountaineerTom]

Congratulations on getting it. Always feels good to figure it out.