2WD won’t engage on 03 Rubicon

[kounty13]

Ok, so I inherited this jeep from my dad, who I never had much contact with. I was told it was rebuilt to be as original as possible, with an engine and transmission rebuild. However I know nothing about jeeps, but I knew I needed to keep it.
With that said, I was driving it the other day and as I was pulling out at an intersection something popped and there was a grinding sound when releasing the clutch. At the time I couldn't get 4wd to work either.
Once I got it home I did find that the shifting z links are bent and not working right so I will switch that, But after manually switching it does move in 4h an 4l. .
So now I'm at the rear differential. Where I hear the noise. I'm unsure if it is a Dana 44, but I did find I have the 231 transfer case so I'm researching what my next step to locate the issue would be.
I have video with the cover off but can't load it.

 

[TheBoogieman]

That's a Dana 35 and it's not a Rubicon. Post any pics you can (shift linkage underneath, rear diff with cover removed, etc.)

 

[kounty13]

That's a Dana 35 and it's not a Rubicon. Post any pics you can (shift linkage underneath, rear diff with cover removed, etc.)

 

[kounty13]

View attachment 551822

I will take more pics tomorrow. I have videos with the differential cover off but rain came in and I can't upload the videos.
It has a salvage title so I'm thinking maybe it was pieced together to just look good and not to original.

 

[macleanflood]

Nice sticker!

Folks do that.

Your 231 and Dana 35 are contra indicators of said sticker.

https://fcagroup.my.site.com/RAM/s/equipment-listing

-Mac

 

[Rubiconned]

View attachment 551822

 

[deadbeat son]

You can buy Rubicon hood stickers.

If you enter the VIN on this website, it will tell you the Jeep's original spec.

 

[kounty13]

I will take more pics tomorrow. I have videos with the differential cover off but rain came in and I can't upload the videos.
It has a salvage title so I'm thinking maybe it was pieced together to just look good and not to original.

 

[TheBoogieman]

 

[5TTTj]

I will take more pics tomorrow. I have videos with the differential cover off but rain came in and I can't upload the videos.
It has a salvage title so I'm thinking maybe it was pieced together to just look good and not to original.

Nice looking jeep, salvage title or not.

 

[deadbeat son]

View attachment 551829

In this second photo, are those wear marks / witness marks from the pinion on the carrier?

 

[kounty13]

Nice looking jeep, salvage title or not.

Thanks. It gets a lot of attention. Just disappointing it's a deep fake. But I think I will eventually work on adding parts to be a rubicon

 

[kounty13]

View attachment 551828

View attachment 551829

It doesn't look worn in person. There was a little bit of metal shavings in the bottom .
Below is my shift links which you can see are bent and not lining up so good. I'm wondering if my transmission mounting bracket is worn and the Trans might have dropped a little.
All the gears seem to be moving fine except there is a grinding noise like they are not fully engaged. Inside the spider gears it kind of looks like the left and right ones aren't moving.

 

[kounty13]

T

You can buy Rubicon hood stickers.

If you enter the VIN on this website, it will tell you the Jeep's original spec.

Thanks I now know it's a sport. Hopefully I didn't pay to much to buy out my sister and keep it. I got it for 5k and that was giving it a 10k value. If I would have know what I know about jeeps now I would have talked it down a little more.
Guess I can build it to be a rubicon.

 

[kounty13]

View attachment 551826

Nice, I haven't named yet, might have to look into something along these lines.

 

[kounty13]

In this second photo, are those wear marks / witness marks from the pinion on the carrier?

I have no experience, but it doesn't look chewed up in person. Those are screen shot from a video I took so kinda blurry. There was a little bit of shavings in the bottom but nothing drastic. I think that gear seems farther back than a lot of pics I'm finding of the 35

 

[Rickyd]

It doesn't look worn in person. There was a little bit of metal shavings in the bottom .
Below is my shift links which you can see are bent and not lining up so good. I'm wondering if my transmission mounting bracket is worn and the Trans might have dropped a little.
All the gears seem to be moving fine except there is a grinding noise like they are not fully engaged. Inside the spider gears it kind of looks like the left and right ones aren't moving.

View attachment 552099

Your shift linkage is extremely misaligned. You need a drop bracket or cable shifter. Notice the z bar is horizontal after the little plate drops it down?

You then loosen the bolt circled in red and adjust the shift linkage properly

My guess is it has a body lift that wasn't done right. The pillow block for the steering shaft under the brake master also needs a spacer with a body lift

 

[kounty13]

Your shift linkage is extremely misaligned. You need a drop bracket or cable shifter. Notice the z bar is horizontal after the little plate drops it down?

You then loosen the bolt circled in red and adjust the shift linkage properly
View attachment 552104

My guess is it has a body lift that wasn't done right. The pillow block for the steering shaft under the brake master also needs a spacer with a body lift

Your shift linkage is extremely misaligned. You need a drop bracket or cable shifter. Notice the z bar is horizontal after the little plate drops it down?

You then loosen the bolt circled in red and adjust the shift linkage properly
View attachment 552104

My guess is it has a body lift that wasn't done right. The pillow block for the steering shaft under the brake master also needs a spacer with a body lift

I did try adjusting that nut but didnt help much. Everything shifted smoothly when I got it. But yes it has a lift, And it doesn't look like anything else was changed. I'm looking into a cable set up now. I'm also checked the Trans mount to be sure it didn't fail and things dropped or were bouncing while driving. The link from transfer case was tied in place with fence wire. I removed so I could figure out the main problem and was able to shift everything manually.

 

[deadbeat son]

I have no experience, but it doesn't look chewed up in person. Those are screen shot from a video I took so kinda blurry. There was a little bit of shavings in the bottom but nothing drastic. I think that gear seems farther back than a lot of pics I'm finding of the 35

Sounds good. It just looked like the pinion had left a mark on the carrier, but it may be a reflection. My eyes aren't what they used to be and the picture is a little fuzzy. I just wanted to make sure you didn't have any contact before you end up like this:

 

[kounty13]

Sounds good. It just looked like the pinion had left a mark on the carrier, but it may be a reflection. My eyes aren't what they used to be and the picture is a little fuzzy. I just wanted to make sure you didn't have any contact before you end up like this:


View attachment 552120

I think it's reflection. Nothing felt grooved, but I will check it closer.