Important

[POLAR_JEEP_04]

Yeah get a estimate. Replacing the solenoid and regulator are easy and then adjust the bands in there too. I'd do that first then if it doesn't fix it you can rebuild it and already have new electronics. Sounds like your second gear band might be loose but I'm not a tranny kinda guy

 

[99SJ_Ex]

The 5.9 is a 46 or 48...

mac '42 = 4.0, 44 = 5.2' gyvr

Thus, shows my inadequate knowledge of them...

 

[Fore Wheeler]

Re: Re: Important

Does T know about this?

As long as I don't come home with any fluid on me, she's okay.

 

[*89Laredo*]

On the subject of zj transmissions...

89"not a zj guy"Laredo

 

[macgyvr]

Does it do it everytime? If you let up a bit like you are shifting a manual does it shift? Could be all of the things we just mentioned for Ben's ZJ.

What motor is it?

mac 'brown fluid usually isn't good tho' gyvr

 

[MKR5150]

Bet that one is junk.

 

[IllianaXJ]

I had a sloppy 2nd gear shift in my 96 ZJ 5.2. Poorboy87 adjusted the bands and it firmed up. Solenoids are a good bet also.

 

[SAMSET]

https://www.novak-adapt.com/catalog/shifters/sk2xc.htm

or

https://www.novak-adapt.com/catalog/shifters/sk2x.htm

Or pull the factory linkage and just clean it up, the 5.9's was a mess when I swapped tcases. I got it apart, cleaned it up with the grinder, greased it, and it was a lot better.

mac 'had the non-cable version in the baby jeep, it was very nice' gyvr

sweet, i was just planning on going OE but you know what they say upgrade what you break.

my plan is to pull off the linkage.
if i can shift the transfer case into different gears then it must be the linkage
right?

if it still will not shift then it must be internal
right?

 

[macgyvr]

sweet, i was just planning on going OE but you know what they say upgrade what you break.

my plan is to pull off the linkage.
if i can shift the transfer case into different gears then it must be the linkage
right?

if it still will not shift then it must be internal
right?

yes, but don't be surprised if it take a little bit of effort to get it to shift, make sure its not bound up and the jeep is in neutral. the stock linkage uses quite a but of leverage to get it to shift so you may need a pry bar/big screw driver/ hammer to get it to move. Don't think cause it won't move easily that is internal.

mac 'at least all the new process cases I've dealt with' gyvr

 

[macgyvr]

PS

I ordered my novak shifter for the baby jeep drunk as a skunk one night in the garage after I couldn't get my stock linkage to line back up after doing floor boards and a tcase swap.

It was a bit pricey, but one of the best under the influence purchases made...

mac 'get the alcohol flowing' gyvr

 

[87manche]

I can shift Jennie's 242 by hand at the lever.

 

[SAMSET]

PS

I ordered my novak shifter for the baby jeep drunk as a skunk one night in the garage after I couldn't get my stock linkage to line back up after doing floor boards and a tcase swap.

It was a bit pricey, but one of the best under the influence purchases made...

mac 'get the alcohol flowing' gyvr

Thats funny. my youngest brother who is scared of the internet was over Saturday night in the garage. after a bunch of liquid courage i got him to say yes to a few things from iron rock offroad for his jeep.

he is super scared of spending money. i had to look it all up and get him to the check out screen, then he still couldn't do it, i had his girlfriend who was sitting right there do it.

it was just a hack n tap and rear shocks...

 

[MKR5150]

Each case is different. I've had some that won't shift unless the jeeps turned off others smooth as butter and some in between. Or the best is when someone puts the wrong linkage in and your tear the case apart just to find it had a 242 link instead of a 231... That week sucked

 

[bwfdrums]

More goats for the MWC

It's a milking stand I swear.

 

[Jeepguy91]

Re: Re: Important

Does it do it everytime? If you let up a bit like you are shifting a manual does it shift? Could be all of the things we just mentioned for Ben's ZJ.

What motor is it?

mac 'brown fluid usually isn't good tho' gyvr

That is exactly how mine is acting. Gonna try and get an estimate done on it to see what's going on with it.

 

[macgyvr]

I can shift Jennie's 242 by hand at the lever.

I'm talking about the tab on the side of the tcase

mac 'there's no leverage' gyvr

 

[MKR5150]

Pliers and a pry bar.

 

[87manche]

I'm talking about the tab on the side of the tcase

mac 'there's no leverage' gyvr

I know what you're talking about.

I can shift the 242 with no linkage attached by hand.

First thing I messed with when her's didn't want to come out of 4wd was the linkage.

 

[ExTankerGuy]

Don't worry so much about air lines. 7 years of running air lockers and never had issues with air lines.

 

[kastein]

Autos aren't terribly bad, you just need to have the mindset going in that everything has to go back together the exact way it came out... I've rebuilt an AXOD; (3) AX4N; a 4R70 and now a 4R100 for complete overhauls. Not counting times I've just gone through valve bodies (Escapes were notorious)...

I have an AW4 I've been toying with the idea of rebuilding, but haven't gotten around to it yet... I've been talking to the local transmission guy and might be working for him during the summer months for a little $$ and as great professional development.

99SJ 'Electronic engines scare me more' Ex

I would scrap that AW4 and spend the scrap money on another in good shape. I can barely give them away over here, they are bulletproof. I sold one for 20 bucks a while ago to a friend of a friend just to get rid of it.

The 5.9 is a 46 or 48...

mac '42 = 4.0, 44 = 5.2' gyvr

46... 47s and 48s are only in fullsizes with V10s or cummins iirc.

yes, but don't be surprised if it take a little bit of effort to get it to shift, make sure its not bound up and the jeep is in neutral. the stock linkage uses quite a but of leverage to get it to shift so you may need a pry bar/big screw driver/ hammer to get it to move. Don't think cause it won't move easily that is internal.

mac 'at least all the new process cases I've dealt with' gyvr

Agreed. The mode fork is spring loaded and rides on the top of the shift gate/cam, even if it is bound up (it is the only one that can really bind up) it will shift just fine, the fork and mode sleeve just won't actually move until the driveline unloads and the spring can do its thing. The range fork is captured in a slot in the gate/cam, it will bind but only if you are in gear while shifting from low to high, which is why the manual says to be rolling slowly in neutral when you shift low to high or vice versa.

You shouldn't have binding issues at all, honestly. It is the linkage if you do, probably gummed up with rust. The spring detents in these cases are pretty stiff but there is a reason for that.

I can shift Jennie's 242 by hand at the lever.

Same but generally only with my thumb.

- Ken 'has a pattern of scars on the back of his right hand from mild tcase induced burns when shifting over the years' Stein