(Solved) - Teraflex 2LO install and 4WD light

[Darkwing327]

So, I just installed a Tera2LOW kit into my 2005 TJ NP231 transfer case. I have a question that those who are familiar with the shift sectors (factory or tera). But first, let me say that this this was dead easy to install with the TC still in the jeep. Two and a bit hours from wheels up on jackstands to down. Don't even have to remove the tail shaft housing which I saw in every install video, but then again, I was not installing an SYE or anything. Took it for a burn and it works as advertised with no drama.

Anyway, to my question. My 4wd light comes on in 4lo, goes off in 2lo. Is off in Neutral. Is off in 2hi. Only glitch I am having is it Is ON in 4hi when initially selecting by pulling up on the lever, but then goes out. Jeep is still in 4hi and everything is fine, but the light is out. If I barely pull up on the 4wd lever it comes back on.

I could live with this the way it is, but are there any adjustments to be made here? I am thinking not because the indicator light and the position of the shifter is not set by the shifter itself (no detents), but rather by the sector shaft and the poppet detent. Thus the poppet in the sector notch sets the position of everything else, including where the 4wd light switch rides on the sector shaft.

Only thing that pops into my mind as I sit here writing this is maybe trying to screw the indicator switch in a little further for better contact. Will go and give that a try, but if anyone else has any thoughts in the meantime, fire away.

 

[Lou]

I had the 2 low before i swapped in a 241 and the light worked fine in 4hi. I really dont see how it could be installed wrong yet still engage all gears easily.

 

[Darkwing327]

I had the 2 low before i swapped in a 241 and the light worked fine in 4hi. I really dont see how it could be installed wrong yet still engage all gears easily.

Definitely not installed wrong, everything 2wd and 4wd works like it should. It's just a millimeter of upward movement on the lever to get the light to come on. So I am thinking that the ball in the switch isn't being pushed quite enough by the ramp on the sector.

Again, just to get confirmation from you as you had one. The entire placement of the sector shaft is controlled by the detent in the notches, correct?

 

[dbbd1]

But first, let me say that this this was dead easy to install with the TC still in the jeep. Two and a bit hours from wheels up on jackstands to down.

Even for a putz like me?

 

[Darkwing327]

Even for a putz like me?

Not sure how to answer that one LOL.

It was all very straightforward, as long as everything comes apart easy, which mine did. As I said, watched a few youtube videos first to get the gist of the innards then put the ass end up on jackstands and crawled underneath. Only thing different from the vids is that I didn't remove the damper (yours may not have) or tail shaft housing, and I left the chain and both gears in the back half of the case that came off, so I never had to do the wiggle/shimmy of the shafts that I saw everyone do by stripping everything out of the back half of the case.

 

[dbbd1]

Thanks.

 

[Darkwing327]

Update on the issue of not having the 4wd light come on in 4hi.

Solution was to remove the 4wd switch from the transfer case and put on a thinner o-ring. I have another one of the Tera2Lo kits here so was able to compare the ramp on the sector shaft with the original I took out and it is shallower by about twenty thou when the 4hi notch is at the engaged position. It just doesn't quite push the ball up in the switch high enough. Easy fix. Hope it helps someone out down the road.

 

[Rescue6]

Nice fix. You will love 2wd low. I use it most of the time actually

 

[B00mb00m]

mine is finicky between 2-hi and 4-hi and in fact will pop out of 4hi after like some miles of driving if i dont kind of make sure its solidly in.