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 Post subject: transfer case not fully engaging
PostPosted: Fri May 25, 2018 11:49 am 
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Location: mansfield missouri
had to use the 4 wheel par-time yesterday and the front wheels were not engaged. I got a whiff of what smelled like an over heated clutch so I disengaged the 4x4 and got out anyway. later I put the part-time in gear on a paved parking lot and it handled like it was in 2 wheel drive. after pulling up on the transfer case lever just a little harder the front wheels were defiantly engaged. not long ago the shift linkage popped off while in full time 4x4.
I put it back on and secured it so it could not come off. I have a feeling the bushing is wallowed out so it needs a little extra umpha to get it to engage. is there a clutch between the transfer case and the front drive? thinking that was what I smelled, like over heated brakes.
thx
I have a new bushing on the way.


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 Post subject: Re: transfer case not fully engaging
PostPosted: Sat Jun 02, 2018 3:03 pm 
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Location: NJ
foxhunter wrote:
had to use the 4 wheel par-time yesterday and the front wheels were not engaged. I got a whiff of what smelled like an over heated clutch so I disengaged the 4x4 and got out anyway. later I put the part-time in gear on a paved parking lot and it handled like it was in 2 wheel drive. after pulling up on the transfer case lever just a little harder the front wheels were defiantly engaged. not long ago the shift linkage popped off while in full time 4x4.
I put it back on and secured it so it could not come off. I have a feeling the bushing is wallowed out so it needs a little extra umpha to get it to engage. is there a clutch between the transfer case and the front drive? thinking that was what I smelled, like over heated brakes.
thx
I have a new bushing on the way.


Which transfer case do you have?

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 Post subject: Re: transfer case not fully engaging
PostPosted: Sat Jun 02, 2018 3:23 pm 
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Location: mansfield missouri
pn242


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 Post subject: Re: transfer case not fully engaging
PostPosted: Fri Dec 07, 2018 12:22 am 
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The ONLY way to guarantee your 242 is in four wheel drive is using four low!

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 Post subject: Re: transfer case not fully engaging
PostPosted: Fri Dec 21, 2018 1:43 am 
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I have the 242 and also had that linkage bushing pop off/disintegrate. The cable and the banjo connector was still there but the plastic bushing that clips on to the shifter/actuator was gone. The transfer case won't engage/disengage without that plastic bushing.

I made my own plastic bushing and locked it on with some C-clips and washers that I bought at ACE.

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 Post subject: Re: transfer case not fully engaging
PostPosted: Sat Dec 22, 2018 12:18 am 
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I made a metal bushing to replace the plastic one and held it on with a spring washer and a small hitch pin. see picture.

[url=https://postimg.cc/k26DfQZm]Image

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 Post subject: Re: transfer case not fully engaging
PostPosted: Sat Dec 22, 2018 11:08 am 
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Picture of installed metal bushing, washer, and clip with lots of copper anti-seize for lubricant:

Image

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Yeti StgIV Hot Tune
Week's BatteryTray
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Samcos/ProVent
SunCoast/Transgo
Carter Intank-pmp
2mic.Sec.Fuel Filter
Flowmaster/NO CAT
V6Airbox/noVH
GM11 Bld.fan/HDClutch
IronrockArms/wwdieselMount

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