Savvy cable shifter didn't fix transfer case engaging 4WD

[Jaime313]

04 LJ with 3.25" SL, no body lift, Teraflex belly up skid and a Transfer case drop down on 35's. I know I need a SYE and DC shaft but I didn't want to put shovel back on since I'm doing the SYE soon. Without the drop down it could vibrate the filling outs of your teeth. Prior to the skid and drop down I would pop out of 4wd (high and low) so I added the Savvy cable. I thought the cable would help me shift smoothly and click into each mode. Nope, there is still some play when pulling the lever just like before the cable but now it doesn't come out of 4wd anymore once I find it but then on occasion getting back to 2WD is tough.
I just bought rear control arms and researching SYEs now. I will be doing the SYE, DC shaft very soon once I decide if I'll attempt it or pay a shop.

Question, does it sound like the TC needs to be rebuilt? Is the 1.25" drop down throwing it off? Someone mentioned the shifter fork? and to replace the chain anyways since it's cracked open.

 

[AndyG]

I would make sure the cable is adjusted correctly, or just remove one end and manually engage it and see how it acts .

 

[Jaime313]

I would make sure the cable is adjusted correctly, or just remove one end and manually engage it and see how it acts .

I hope that’s all it is instead of a Transfer case rebuild.

 

[AndyG]

I hope that’s all it is instead of a Transfer case rebuild.

Absolutely...I recently put an expensive borgeson steering shaft on my Jeep thinking that I have bad steering u-joints and it turned out that it was my track bar mount popping.

Be sure as you can it may be a little hard to do it by hand but you can definitely get it in each mode by hand if there's no internal issue.

 

[MaloStapalo]

I would make sure the cable is adjusted correctly, or just remove one end and manually engage it and see how it acts .

Maybe its just me but I have had a tough time getting my savvy cable adjusted correctly. I am also trying to do it by myself, I'll have my wife hold the shift into 4lo today and see if that makes it easier to adjust. 2h, 4h, are fine but it wants to pop out of 4lo

 

[AndyG]

Maybe its just me but I have had a tough time getting my savvy cable adjusted correctly. I am also trying to do it by myself, I'll have my wife hold the shift into 4lo today and see if that makes it easier to adjust. 2h, 4h, are fine but it wants to pop out of 4lo

I like to set it up backward... Put the transfer case in 4 low firmly.

Pull the handle all the way up.

Then install / adjust the cable to that fitment... Now firmly engaged for low is your baseline and everything else should take care of itself.

In this scenario you should need no extra slack on the transfer case end as you have the cable exactly where you want it to be and the lever...so what you're looking for is when you slightly move the handle downward it immediately moves the cable...this is going to ensure that you get all the throw that you need to get back down to 2 hi

 

[astjp2]

Are you trying to shift on dry pavement? If so, that is part of your problem

 

[MaloStapalo]

I like to set it up backward... Put the transfer case in 4 low firmly.

Pull the handle all the way up.

Then install / adjust the cable to that fitment... Now firmly engaged for low is your baseline and everything else should take care of itself.

In this scenario you should need no extra slack on the transfer case end as you have the cable exactly where you want it to be and the lever...so what you're looking for is when you slightly move the handle downward it immediately moves the cable...this is going to ensure that you get all the throw that you need to get back down to 2 hi

That's a really good idea. Thank you!

 

[dbbd1]

And, two 15/16" stubby open end wrenches really help.

 

[MaloStapalo]

I like to set it up backward... Put the transfer case in 4 low firmly.

Pull the handle all the way up.

Then install / adjust the cable to that fitment... Now firmly engaged for low is your baseline and everything else should take care of itself.

In this scenario you should need no extra slack on the transfer case end as you have the cable exactly where you want it to be and the lever...so what you're looking for is when you slightly move the handle downward it immediately moves the cable...this is going to ensure that you get all the throw that you need to get back down to 2 hi

O I think this worked. Took it out to a trail head and had good engagement in 4lo, and lockers engaged. Thank you so much I was getting so frustrated with this!

Now to change my TC fluid and see how much metal flakes I created.

 

[MaloStapalo]

And, two 15/16" stubby open end wrenches really help.

Yup I couldn't find stubby so I used a cut off wheel and hacked it down.

 

[AndyG]

Yup I couldn't find stubby so I used a cut off wheel and hacked it down.

Yes sir, good post. , I made one and carry it in my my trail kit..,because if I ever needed to adjust the cable I’d be in trouble. Not likely to be needed, man the cable is a true upgrade .

4 lo is the one gear that will jump out if you aren’t fully engaged , every time .

 

[Jaime313]

I like to set it up backward... Put the transfer case in 4 low firmly.

Pull the handle all the way up.

Then install / adjust the cable to that fitment... Now firmly engaged for low is your baseline and everything else should take care of itself.

In this scenario you should need no extra slack on the transfer case end as you have the cable exactly where you want it to be and the lever...so what you're looking for is when you slightly move the handle downward it immediately moves the cable...this is going to ensure that you get all the throw that you need to get back down to 2 hi

I’m gonna try and re-install it again. Thanks for the tips

 

[Jaime313]

Are you trying to shift on dry pavement? If so, that is part of your problem

On a dirt trail

 

[Jaime313]

Thank you guys for the help, I hope that it works when I try the reverse re-install. I still think I’ll replace the chain when I do the SYE.

 

[AndyG]

Let us know man.

 

[Jaime313]

Let us know man.

Will do

 

[Boinked]

I know i read something that says to install it in 4lo. But for the life of me i can't find it.

I know novak says do it in 2hi. But i know that I did mine in 4lo and have no issues with it popping out.

 

[Jaime313]

I know i read something that says to install it in 4lo. But for the life of me i can't find it.

I know novak says do it in 2hi. But i know that I did mine in 4lo and have no issues with it popping out.

That day was busy, we did the cable, welded my tire carrier and had to play with the shroud after I added the Teraflex belly up skid. I do t remember if we did it in 4lo or 2h. So I’m gonna recheck it in 4L and see how it goes.

 

[AndyG]

The catch is you really have to be sure you are engaged fully or you're going to give yourself a false starting point so to speak.