Just installed a replacement AW4-having problems

[BIGSLVRXJ]

Hey guys,

1998 XJ, AW4, NP242, D30, C8.25

It's been a while since I've asked for help in the tech forum but this has me stumped. I just bought a 1998 XJ that was advertised as having a bad transmission. The old transmission was already removed when I got it and there was one from a salvage yard included in the sale. The salvage yard trans was supposedly good and had 120k.

I noticed when I was prepping the "new" trans to go in that the torque converter was low on fluid, not to the top like they usually are. Like a dummy, I forgot to add fluid to it before putting it in, but I don't think at this point that that could cause the problems I'm having.

Here are my symptoms:
-I have now added 7 quarts total of fluid and it will not engage in any gear. When the shifter is in gear it idles up like it's going to engage but it doesn't. I have cycled through all the gears and the fluid level is between the two holes on the dipstick when warm.
-It grinds when going from reverse to park but it won't grind if I go straight from Neutral to Park.

I'm starting to believe that there is an issue with the transfer case. When I was doing a fluid change on the transfer case I stuck my finger in the drain hole to try to hurry the fluid along and I noticed something move. I pushed it about an inch to the front, it sprung back, did it again and it got stuck and didn't spring back. Is that the chain?

Also, now I am relatively sure that the case is in "Part Time" selection but the Jeep will roll forwards and backwards like it's in Neutral and the transmission is in Park. So I don't know if I managed to shear the park pin or if the case is at fault.

So in my mind I have narrowed it down to 3 things.
-Transmission needs more fluid and just hasn't cycled it all the way through. However I would think 7 qts would be enough.
-Transfer case is shot.
-Transmission is shot.

Any thoughts?

Thanks in advance for reading my long winded post, any help is greatly appreciated!

-Collin

 

[Shorty]

it sounds as though the transmission isn't doing anything past it's output shaft-- you are getting movement in the trans when ingear since it's noisey when shifting into park from a foreward gear.

Make sure (as opposed to being fairly sure) that the transfer case is in a mode other than neutral, and then you're looking for reasons that the trans output shaft isn't turning the transfer case.

 

[BIGSLVRXJ]

it sounds as though the transmission isn't doing anything past it's output shaft-- you are getting movement in the trans when ingear since it's noisey when shifting into park from a foreward gear.

Make sure (as opposed to being fairly sure) that the transfer case is in a mode other than neutral, and then you're looking for reasons that the trans output shaft isn't turning the transfer case.

Thanks for your response. I will verify that it is in a selection other than neutral. If it is in fact in a position that should be engaging it would I be looking towards the transfer case as a culprit?

 

[Shorty]

or improper connection between trans and transfer case (wrong output shaft on trans or incorrecr length or spline count on T.C. input shaft)

 

[BIGSLVRXJ]

or improper connection between trans and transfer case (wrong output shaft on trans or incorrecr length or spline count on T.C. input shaft)

So when it's in 4x4 it will spin the front yoke (on the case) but will not spin the rear. Does this mean there is a part broken in the transfer case?

 

[Digger87xj]

1st tell-tail the trans it trying to work is the grind you get from neutral to park.

You need to focus on the t-case. Probably the entire problem from the get go and the previous owner mis diagnosed.

 

[Digger87xj]

Re: Re: Just installed a replacement AW4-having problems

So when it's in 4x4 it will spin the front yoke (on the case) but will not spin the rear. Does this mean there is a part broken in the transfer case?

Not necessarily. Without resistance the 242 will do that. Put it in 4lo and see what you get.

 

[BIGSLVRXJ]

Thanks to both of you guys for the help, turns out the transfer case main shaft was broken. Got er up and running