New to me 2001TJ SE manual 5 speed. Drives fine in 2WD. Was out today with a friend and could not get it to shift to 4H or 4L. By that I mean the shift handle wouldn’t budge at all. I disconnected the linkage and then the handle moved freely. I hit all the joints for the linkages underneath and beside the transfer case with lube. Let them sit, hooked it back up and it still stuck. Tried it in gear, in neutral, rolling slowly forward and reverse… nothing. Is it possible the linkage that directly attaches to the transfer case is frozen up? Should I try a gentle tap with a rubber mallet? If it was functioning properly should I be able to switch it by hand from underneath if all other linkages are disconnected? Any advice is very much welcomed!
2001 TJ Transfer Case Not Shifting
- Thread starter 01TJ4cl
- Start date
Yes, you should be able to move it by hand when disconnected.
Assuming you are moving it the right direction.
Mine the handle frozen removed the console to expose linkage and z gate heat and pb blaster starting to make progress will at least go into 4h now
I unhooked everything today down to just the small shift linkage coming straight out of the transfer case. Cleaned it well with brake cleaner and then hit it several times with Liquid wrench. I still was not able to get it to move. I checked my direction on a friend TJ to make sure I was trying to move in the right direction and I was. I lightly tapped it with a hammer and still got zero movement. How screwed am I if I ever want to use 4WD again?
Sorry basics: Where is GTMO ? 2001 = 2.5 = AX-5 Is trans in neutral ? Jack up rear ends and spin drive shaft and see if that helps.
That is what I would do, might be wrong. Removing a TC is not all that hard if need be. D
That is what I would do, might be wrong. Removing a TC is not all that hard if need be. D
This video demonstrates how a cable shifter works...but most importantly shows you the normal motion of the shift arm on the transfer case. Mine is really stiff...takes a lot of effort to move it sans shifter.
-Mac
-Mac
Sorry, GTMO is a Navy Base in Cuba… limited resources for jeep work. I’ll try to jack up the rear wheels but even when rolling slowly in forward or reverse it hasn’t seemed to make a difference.
Thanks for the video, that helps. I tried even tapping that little linkage with a hammer and still could not get any motion there. I sprayed it with a lot of liquid wrench and I think I’ll continue doing that over the next couple days and continue to try to get some movement there. Found the attached picture on another site and circled the part I’m talking about in red.
I see new bolts holding the transfercase on. It has been off recently. Is there any evidence of the case being apart? Maybe it was assembled wrong by someone. They are easy to dissassemble
Disconnect the linkage to that TC lever (circled in red). Grab the lever with Channel-Locks or a big adjustable wrench, and move it by hand. With the extra leverage you should be able to feel what it's doing, vastly better than trying to move it by hand.
If I am seeing correctly, the whole shift assembly is out of whack and hitting the side of the transmission.
https://wranglertjforum.com/threads/transfer-case-linkage-issues.71811/
https://wranglertjforum.com/threads/transfer-case-linkage-issues.71811/
Last edited:
It looks like he has it jacked up way too high for it to move. Or it had a body lift and that drop plate wasn't removed when the pucks were
Sorry for the confusion guys, that picture is not my Jeep just one that I found online to demonstrate the piece that I was trying to move by hand. From the sound of things I’m either going to have to live with a 2 WD Jeep or find the time to drop the transfer case. Because I live overseas on a military base, parts are hard to get so is there a kit for a complete transfer case rebuild that would include the chain and all of the seals and bearings in one place to a purchase as a kit?
Not convinced you need a rebuild yet. Call Advance or Novak and see what they say about troubleshooting.
Or maclean
Or maclean
Last edited:
You got a shop on base for doing your own repairs?
I'd disconnect your linkage and see if you can operate the lever.
Next I'd drop the skid plate and lower the transfer case and transmission a bit and see if you can actuate the lever.
If that didn't work then I'd disconnect each driveshaft and see if you can rotate the front yoke on the transfer case and get it to shift.
Then I'd drop the case, check function and proceed to dismantle.
I had to reassemble my transfer case four times before I figured out the oil pump was binding on assembly causing shift issues like you are describing.
How's the ATF look inside?
Pictures of your situation might help.
Do you have a drop on the skid plate?
-Mac
I'd disconnect your linkage and see if you can operate the lever.
Next I'd drop the skid plate and lower the transfer case and transmission a bit and see if you can actuate the lever.
If that didn't work then I'd disconnect each driveshaft and see if you can rotate the front yoke on the transfer case and get it to shift.
Then I'd drop the case, check function and proceed to dismantle.
I had to reassemble my transfer case four times before I figured out the oil pump was binding on assembly causing shift issues like you are describing.
How's the ATF look inside?
Pictures of your situation might help.
Do you have a drop on the skid plate?
-Mac
Mac,
Thanks for breaking that down for me, that will be helpful.
I have disconnected the linkage and I am unable to operate the lever by hand.
I will try to drop the skid plate and slightly lower the transmission/transfer case this weekend to see if that makes a difference and if not, I will continue with what you recommended.
If I’m going to go to the trouble of dismantling the transfer case then wouldn’t it be wise to go ahead and order a complete rebuild kit with new chain, bearing seals, etc.?
I have not yet checked the ATF inside of it, it has been pouring down rain since shortly after making this post so I’ve not got underneath to take any pictures or check the fluid. I will try to get that in the next day or two if the rain lets up.
Sure if you want. But that's a lot of work with a press and bearing pullers.
I didn't rebuild mine when I did a SYE. 230k miles and it was fine. Plus all new parts are shit...I'd rather have the originals than gamble the new ones will function.
My pet theory... mostly because I did it...and I see lots of posts from others...is a previous owner took it apart, and put it back together wrong. I'm guessing it's the oil pump not getting seated correctly on the main shaft...that binds up the shift fork.
I'm guessing your out a couple of hours of time and a tube of RTV.
If you really want to order and replace something get a new Anchor transmission mount. I'll bet you have the original and 20 plus year old rubber is crap.
-Mac
Similar threads
