I had my girlfriend cleaning the center console, car off and in park and she pulled the Transfercase shifter from 2hi to 4hi to clean up underneath and around it....

I didn't realize it, backing out of space and turning I felt it and heard the normal winding sound and realized I was in 4hi, but no light was on.....

I shifted back to 2hi, and the part time light came on



I drove to a bigger parking lot right across the street, thinking maybe something wasn't aligned/shifting properly....

playing with it in neutral+running, going from 2hi-4hi-N-4lo, it seems like in N it says it's in 4LO sometimes, being very finicky and sensitive.

I had it in 4Hi to see if it was just a sensor/light or if it was actually in 2hi, but then I started hearing a clicking sound coming from underneath, seeming to accelerate with speed (only up to 5-10 mph)

I went to neutral, put it in 2hi, part time light still coming in, and then I heard the clicking again...


Looking underneath the jeep, I couldn't see anything obvious, the firewall near the Ujoint on rear seemed that it may be close enough to click, so I bent it away from it, and then noticed the TCase has a very slow leak probably the gasket or one of the nuts?

After this 10 minute laying on pavement sighing and actually thinking I could see a problem, I started back up and so far (drove a few miles) have not noticed clicking, but the part time light still remains lit even in 2hi...

Reverse, D, 1, 2, all seem to be shifting and driving fine, and i'm sure that horrible clicking sound will be back

No it's not CV axle click/during turns, definitely from transfercase area

Thoughts, concerns, questions....

Definite need of transfercase flush, replacing gaskets in process......

I've seen there is a set of bushings/linkage responsible for this?

I see Mopar part 5083138AA is the switch, which isn't the biggest deal to me for now, if it's physically riding in 2hi even though it says part time, I guess the grinding sound got me the most upset, but now I don't hear it

I swear this fu$$ing jeep fixes it self on a lot of different issues so far!

there is a switch on the bottom of the transfercase i believe that controls which lights pops up when you move the selector. All it does is show what gear you are in, but sometimes it gets knocked off by one gear forward or backwards so that when your in part time, it says full time, or neutral it says 4lo. If you have the manual shifter where you manually put it into 4wd(i think selectrac but i cant remember) it doesnt matter. If you are in 2wd on the shifter, it is truly in 2wd, same goes for all of the other gears.

_________________
06 CRD limited
Frankenlift, JBA 1/4 top plate, 3 clevis rings, 3 stacked iso's
JBA UCA and quick disconnects
Procomp rockkrawlr 16x8 4.25bs with 265-70-65 General Grabber AT2's
Mopar full skid plates, JCR stage 3 Rock Rails
Kenwood HU, 6.5 pioneer marine grade door speakers, JL stealthbox kenwood amp
GDE HOT tune
Soon to come
RL Rock monitor bumper

the switch is on Top of the xfer case (oh how I wish it were on the bottom. Also someone correct me if I am wrong but all KJs have the manual transfer case shifter.

_________________
Current Jeeps:
2004 KJ Sport, 1977 CJ-5 Renegade
Jeeps I no longer have:
2003 KJ Limited, 2002 KJ Renegade, 2002 KJ Sport 2WD, 2002 KJ Sport, 2000 XJ SE 2WD, 1998 ZJ Laredo, 1996 XJ Country , 1990 YJ, 1991 SJ Grand Wagoneer, 1979 SJ Wagoneer
Projects I am looking for:
1996-2001 XJ, 1980-1988 AMC Eagle Wagon

Never seen a kj without manual shifter for transfer case. I know its physically in 2wd, im almost scared to mess with it tillim ready to have it diagnosed.
Seems to be running fine in 2wd, the switch ill change later.


Any one got another thread with tcase pics, things to look for, how to check the linkage, etc? Still dont know why she was clicking in 4wd.

Could low tcase fluid do this? Going to go clean tcase real good to pinpoint leak.

viewtopic.php?f=3&t=59788

_________________
-dbk
SOLD2007 6 Speed - Projector Retrofit -Custom LED Tail Lights - Lights on Cowl & 130w 8" ProComps - Full Skids-RockLizard Super Skink Sliders-Front Hitch
Frankenlifted-Al's A-Arms-Goodyear Duractracs 31x10.5R15x7 Cragar D Window 4"bs-Cobra 75WXST - 4' Firestick
4.10s sitting in a box - 3
Sold-1988 Suzuki Samurai
2002 Jeep TJ

Yeah, the switch I can live with, the sound I heard that night, maybe not. I haven't bothered with it yet, but im pretty sure my 4wd is going to be noisy... Anyone got input on the linkage, where it is, how to check?