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91 cherokee transfer case issue

Old Nov 23, 2015 | 04:14 PM
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Year: 1991
Model: Cherokee
Engine: 4.0 HO
Default 91 cherokee transfer case issue

Once in awhile it would pop out of gear and grind from 2HI. id turn it off and on and all would be fine again. Started happening more and the rear seal is leaking so the fluid got low.

Now after filing it and running fne for about 50 miles it will grind in all modes but 4LO.

The lever was always spongy. I put new bushing in the adjusting lever and held it back with a bungee cord to adjust it. Also tried it with the 1/8" spacer as the manual states. Also aligned it with the old wera marks. All to no success.

I see form a manual there are wires and vacum lines going into it. Could that cause the grinding to happen. Cant seem to find out what they are for.

Any other ideas welcome.

How fast is ok in 4lo on pavement?

Thnaks
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