Jeep Wrangler TJ Full Electric Conversions

Transfer case lever doesn't feel like it's connected to anything

Silverback9098

Silverback9098

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Original poster
Joined
Mar 14, 2022
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Location
Baltimore, Maryland
I just bought my first Jeep, a 98 TJ 2.5 L with a manual transmission. It needs a little TLC, and I knew that going in. The used rear end was put in by the previous owner and I just had a front drive shaft installed. Right now the 4WD does not work because the 4WD Transfer Case Lever doesn't feel like it is hooked up to anything? I've looked underneath and I don't know what the deal is? Ideas? Possible causes? and Possible cost would be greatly appreciated?
 
The factory linkage is ok for what it is. Yours likely just slipped out of adjustment. It only takes a 1/2" wrench to loosen the bolt that holds it in adjustment, put it back into adjustment then tighten the snot out of the bolt.

That bolt is circled in red red below.

transfer-case-linkage.webp
 
Jerry's got the answer and he's probably right, unless that bolt, or more, is missing which could be why it "doesn't feel like it is hooked up to anything."

It's always hard to tell what a previous owner has done, a least we know the transfer case is there or you'd have had nothing to connect the front driveshaft to.
 
Silverback9098 said:
I just bought my first Jeep, a 98 TJ 2.5 L with a manual transmission. It needs a little TLC, and I knew that going in. The used rear end was put in by the previous owner and I just had a front drive shaft installed. Right now the 4WD does not work because the 4WD Transfer Case Lever doesn't feel like it is hooked up to anything? I've looked underneath and I don't know what the deal is? Ideas? Possible causes? and Possible cost would be greatly appreciated?
Click to expand...
Watch out for non matching gear ratios. Maybe the rear axle was replaced with one that doesn’t match the front
 
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Once 4wd can be engaged it's easy to see if they match. On a flat dry surface shift into 4wd, hi or lo, and put any transmission (manual or auto) in neutral, then push the Jeep forward or backward by hand. Matching ratios should push pretty easy with one hand. If it feels like it's in park, good luck moving it at all because those ratios don't match.

I'll also add that tire sizes are the rubber version of gear ratios. I've experienced both mis-matches separately and my current CJ was raced with bigger tires on the rear so it sits still in 4wd but I haven't checked the ratios yet. Who knows it might be both the tires and the gears on that one.
 
JEEPCJTJ said:
Once 4wd can be engaged it's easy to see if they match. On a flat dry surface shift into 4wd, hi or lo, and put any transmission (manual or auto) in neutral, then push the Jeep forward or backward by hand. Matching ratios should push pretty easy with one hand. If it feels like it's in park, good luck moving it at all because those ratios don't match.

I'll also add that tire sizes are the rubber version of gear ratios. I've experienced both mis-matches separately and my current CJ was raced with bigger tires on the rear so it sits still in 4wd but I haven't checked the ratios yet. Who knows it might be both the tires and the gears on that one.
Click to expand...
Much appreciated!
 
Pinion seal leaks are generally no big deal but what the hell is that ooze coming out of your diff? Have you done any water crossings recently? The other one looks fine.
 
Silverback9098 said:
I have no idea!?
Click to expand...
At a minimum I'd take out the fill plug in the diff and stick my finger in there. It should look like oil and not chocolate milk. Gear oil in general doesn't have that thick brown color too it unless it has water in it. I'm not an oil expert but I'd be concerned you have water in the oil. Other people probably have better knowledge about this and I guess since nobody else has said anything it can't be that bad?
 
Silverback9098 said:
Think I found the problem!

View attachment 317773
Click to expand...

That'll do it. There are rubber/plastic bushings that those rods snap into and they can break, leaving nothing to hold the linkage, or even more annoyingly, they'll be there and look ok and you'll spend a bunch of time cramming your hands up there to put it back together only for it to pop right back out the first time you try to shift it.
 
pagrey said:
At a minimum I'd take out the fill plug in the diff and stick my finger in there. It should look like oil and not chocolate milk. Gear oil in general doesn't have that thick brown color too it unless it has water in it. I'm not an oil expert but I'd be concerned you have water in the oil. Other people probably have better knowledge about this and I guess since nobody else has said anything it can't be that bad?
Click to expand...
Yep. Thanks
 
pagrey said:
At a minimum I'd take out the fill plug in the diff and stick my finger in there. It should look like oil and not chocolate milk. Gear oil in general doesn't have that thick brown color too it unless it has water in it. I'm not an oil expert but I'd be concerned you have water in the oil. Other people probably have better knowledge about this and I guess since nobody else has said anything it can't be that bad?
Click to expand...

Yes, and having water in the diff fluid would definitly cause the bad bearings and races I saw in the pics on your other post.
 

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