So I did the vacuum disconnect mod, locked the shift fork into the 4x4 position and put it all back together. Now I'm having an issue with it staying in 4hi when it's supposed to be in 2wd, meaning the front axle is still live. Light goes out like normal when 2wd is selected. Followed the write-up and everyone went smoothly. I'm gonna check the linkage here in a minute but I'm guessing that's not the issue. Anybody done this mod and have the same issue? One thing I did was leave all 3 vacumm lines hooked up at the front axle because the write-up said nothing about having to mess with them, maybe that's the issue? Anyone got any ideas?

 

I always reverse after taking it out of 4x4. This always seems to help to make sure the transfer case completely disengages.

 

Tried that, backed up almost 75 feet just to make sure. Even cycled her in and out of 4 and tried backing up a couple more times to no avail.

 

Hey Catch. Btw, I'm just over the hill in CC. The 4w light switch gets vacuum after the sleeve moves over, providing vacuum to that switch. A pretty neat setup I thought. That's why 3. One to pull in , one to pull out, and one to send, (divert) vacuum to the switch when it's actually over.


After messing with it forget the light, unless there is a companion mod to the vac switch on the TC that I have not seen. I'm just thinking now, maybe run the vac that did go to the disco to engage, to the switch. I haven't thought that through myself....yet! (and Yea, you gotta back up!)

 

Hmmm, I don't see how that would change anything since the shift fork is permantly in the locked position so all the vacuum lines don't really matter anymore. It's almost like my transfer case isn't disengaging since the mod but there is no reason why it should be doing that. Before the mod it disengaged the axle perfectly, it was just having issues engaging %80 of the time so I did the mod. I'll dig into it tomorrow and see if I can troubleshoot it a bit more unless anyone has any other ideas.

 

Could the transfer case have been staying in 4hi all along but when the disco disengaged it wasn't acting like it was still in 4hi?

How do you know it is still locked in 4hi now? Is it jerking when on pavement or steering hard?

 

I was thinking the same thing actually, I've never heard of a 231 going out or having issues like that before though. All the linkage is adjusted and operating correctly. And yes it jerks when turning sharp, I know for a fact it's stuck in 4wd. I took it wheelin' earlier today and in 2wd the front axle is completely live, I tested it out thoroughly.

 

What about Neutral and 4Lo?

If you shift into those and it stays in 4Hi, then maybe something is wrong inside the case and the selector isn't moving the forks inside.

 

Neutral and 4lo work perfectly, it just doesn't want to come out of 4wd.

 

I guess I might check the juice in the case, and maybe jack the fronts off the ground so I could really see if they are engaged or not. Check the linkage/position.

 

Whoa. Wait a minute.Is just the fact that the front driveshaft turns in 2wd bugging you? Or is the Jeep bucking around corners on hard pavement like 4wd is still engaged?

 

Put in 2wd pull front shaft at pinion yoke ,see if it spins .

 

Are you shifting like you're supposed to?

Here's how the factory suggests you shift the transfer case and I've been doing this since these things were new and I worked at the dealership. Quoted from the owner's manual.

"To engage, shift the transfer case lever from 2H to 4H while the vehicle is moving at any legal speed". I let off the gas, throw the lever, and then tap the gas and let off.

4L position: " To engage, slow the vehicle to 2-3 MPH , shift the transmission to Neutral, then shift the transfer lever to the right and pull firmly rearward to 4L".

 

Cruiser, yes it bucks. It is stuck in 4hi, I know that without a doubt. I'll check the fluid level in the case shortly. And yes that's how I always shifted my XJ's into 4wd, that's how they were designed, a shift on the fly case.

 

Had to ask. Check the fluid, top it off, and try shifting back to 2wd on some dirt.