I have a 91 xj.the problem I'm having is when I put it in 4wheel drive it pops (sounds like the chain is jumping ) plus when I'm driving in 2 wheel drive the transmission tunnel gets hot ( thinking from the transfer case) and it is full of fluid. Any ideas?

 

the heat can come from many things (exhaust leak, friction inside trans or tcase, etc.). What does the fluid look like in the trans and the tcase? Popping is bad. How many miles are on the tcase chain? Has it been replaced?

 

2 things.

Are you shifting it correctly?

Are your motor/trans mounts bad causing the issue?

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. The suggestions in ITALICS are mine.

"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".

To shift out of 4L, shift the transmission into neutral with the vehicle stopped, shift the transfer case lever to 2H, then to D if you have an automatic, or into first gear with a manual, and continue on.


Revised 01-31-2014