Transfer care woes + post V8 magnum swap shake-down issues

PirataCoqui

TJ Enthusiast
Original poster
Supporting Member
Joined
Nov 4, 2021
Messages
141
Location
Raleigh NC
Context: Completed V8 5.9 magnum swap about a year and a half ago, but have only done limited off-roading. This weekend, I spent wheeling with my kid, and a few post-build issues came up, one of which left me stranded.

Issues:
1, While going down a hill off and slightly off-camber, I heard a pop and then a rattling sound. I was in 4LO. I l could not move forward, nor reverse, was stuck off-camber, this was afther doing light wheeling for about 2.5 hours, nothing crazy.

I had to winch myself out, and given that I was on a hill, it was an important lesson about making sure your e-brake is properly adjusted (mine wasn't). I was able to get it to engage in what physically looks like the 2wd position(I have a Savy shift linkage), but it immediately popped out of gear, and I had no reverse. After messing around with it, I found that I could get it to stay in 2WD IF I forced the lever down and prevented it from popping out. I found a flat spot on the trail and did the following:
  1. Removed linkage and manually tried to move it firmly into 2wd, but failed; it would keep popping out, but then noticed a weird thing: my 4wd idiot light would come on.
  2. If I tried to engage 4l, it would move into position, but the jeep acts like it's in neutral.
  3. I had to rev the engine, at which point I would hear a rattling sound and then push the 4x4 lever forward to engage 4x4, but unless I held it down, it would pop out of gear. Sometimes it would make a loud popping sound and no amount of holding the lever in place would keep it in gear.
  4. It was easier to make the transfer case engage while it was in gear and slowed down vs in neutral (i could not get it to engage)
Where should I start? Did I grenade the transfer case? I did sye kit when I did the v8 swap, did I mess something up?

2, The brake chime would come on when off-camber, even with full liquid.
  • found a small leak on one of my rear caliper hoses. I expect the brake light is coming on because of a pressure difference. I want to do a big brake kit upgrade since I am going to be messing with my brakes. I am much heavier now than when I was, and I usually carry a full load. I have 17-inch wheels, and run 35's with no real plan to go higher. Suggestions on which Black Magic kit to get?
3, The steering box started a small leak
  • Tried the Lucas stop leak as suggested by a few here, but it's still there, and other suggestions?


All things considered, we had a great weekend and enjoyed spending time with my 5-year-old; it was also my first time using my winch.
 
  • Like
Reactions: macleanflood
This is where we broke

IMG_5045.jpg
 
  • Wow
Reactions: AOSJ
Honestly sounds like the shift cable is out of adjustment.

Can you disconnect the cable and successfully shift the t-case?

-Mac
 
Honestly sounds like the shift cable is out of adjustment.

Can you disconnect the cable and successfully shift the t-case?

-Mac

Tried doing that, disconnected while on the trail, and it was very hard to get it to engage. I never got the satisfying click into place I usually get (had to engage 4wd manually before with the factory shifter, which started giving me problems).
 
You didn't say which transmission you are using..
I'm going to assume you have a 46RE behind the 5.9? Did you do anything to the transfer case when you were dong the swap?

My first guess is that the bushings on the shift fork are worn or gone.. My second thought is along with Mac that the shifter is out of adjustment.
If you haven't done so yet I'd suggest a Savvy or Novak cable shifter for your transfer case.

BTW I had a Magnum swapped in my TJ prior to doing a Hemi swap so I understand all the fun of these swaps.

Edit: I thought you were doing a 5.2 swap? Did something change? The 44RE or the 46RE doesn't matter for most things but knowing what you have would still help us figure out what is going on.
 
Last edited:
There's a bolt like tube on the bottom of the t-case that holds a spring and ball that engages the detent in the transfer case to hold it into it's four positions.

You could pull that and see if it shifts.

That's a low point drain for fluid...so be ready.

-Mac
 
You didn't say which transmission you are using..
I'm going to assume you have a 46RE behind the 5.9? Did you do anything to the transfer case when you were dong the swap?

My first guess is that the bushings on the shift fork are worn or gone.. My second thought is along with Mac that the shifter is out of adjustment.
If you haven't done so yet I'd suggest a Savvy or Novak cable shifter for your transfer case.

BTW I had a Magnum swapped in my TJ prior to doing a Hemi swap so I understand all the fun of these swaps.

Edit: I thought you were doing a 5.2 swap? Did something change? The 44RE or the 46RE doesn't matter for most things but knowing what you have would still help us figure out what is going on.

I did 5.9 with 46RE off a 2001 Dodge Ram. @Wildman I might have posted incorrectly, but it was always the 5.9. You helped me work out the shift linkage issue + load of other little stuff when I was in the midst of the swap.

Edit: Already running the Savy cable

I did this-—>
NP231J HD Super Short SYE w/1310 CV Yoke16-1201-1945

I tried to install the chain from the ram, but failed at it and ended up using the same one. I might have put something together wrong, don't know. I've driven it about 2K miles since the swap, all on-road, but this is the first real wheeling trip where it spent a ton of time on the trails all weekend, and the first time it's been almost fully vertical, which could have shifted inside(maybe?)
 
Last edited:
There's a bolt like tube on the bottom of the t-case that holds a spring and ball that engages the detent in the transfer case to hold it into it's four positions.

You could pull that and see if it shifts.

That's a low point drain for fluid...so be ready.

-Mac

Thans mac, will give that shot and see what happens :), assuming it does shift, what does that tell me?
 
  • Like
Reactions: macleanflood
I did 5.9 with 46RE off a 2001 Dodge Ram. @Wildman I might have posted incorrectly, but it was always the 5.9. You helped me work out the shift linkage issue + load of other little stuff when I was in the midst of the swap.

Edit: Already running the Savy cable

I did this-—>

NP231J HD Super Short SYE w/1310 CV Yoke16-1201-1945

I tried to install the chain from the ram, but failed at it and ended up using the same one. I might have put something together wrong, don't know. I've driven it about 2K miles since the swap, all on-road, but this is the first real wheeling trip where it spent a ton of time on the trails all weekend, and the first time it's been almost fully vertical, which could have shifted inside(maybe?)

OK, your thread on the swap said it was a 5.2 & 44RE... But that doesn't matter now.

My guess is you've got something internal that needs to be adjusted or moved. I messed mine up the first time I tore it apart.... Follow Mac's thread on his leaky t-case as he covers assembly and things too.
 
  • Like
Reactions: macleanflood
 

I think he's going to have to disassemble it and verify it's assembled correctly from the description of the way it's acting.
 
  • Like
Reactions: macleanflood
I just noticed I got the moment it happened on video(my kid wanted to send the video to his mom)... ignore the music, it's pretty loud when it pops out and starts grinding and can be heard over the music.
Just hopefully not a few dozen times like I did...

-Mac

Starting reading up on your thread, man, that was an odyssey.
 
  • Like
Reactions: Wildman
I just noticed I got the moment it happened on video(my kid wanted to send the video to his mom)... ignore the music, it's pretty loud when it pops out and starts grinding and can be heard over the music.


Starting reading up on your thread, man, that was an odyssey.

Load your video on YouTube then link it here...Makes it easier for people to watch.

Edit: Make sure to post up when you get it apart or figured out... Might help out others.
 
Last edited:
  • Like
Reactions: macleanflood
My guess is assembly error.... I'd pull it out and disassemble it.

First I'd try manually shifting it just to verify. But I'll guess it's internal.
 
  • Like
Reactions: macleanflood
My guess is assembly error.... I'd pull it out and disassemble it.

First I'd try manually shifting it just to verify. But I'll guess it's internal.

I am with you. Hopefully I didn’t grenade it. What you end up doing for brakes on your rig ?