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Not a lemon, just the way it typical operates. Mine has done it a couple times till I figured out what was going on. I know it sounds weird, but that is the way it goes, it more of a truck transfercase than the 4wd used in most other SUVs.
The select-trac has a tendy to pop like that if it is not shift correctly. Its a little tricky and odd, but onces you understand what is going on it is fine. The t-case case was still in part-time 4wd and that is why it was binding. It finally slipped out with all the drive train binding and made a pop.
The lever works by loading a spring inside the t-case The spring does the actually shifting in the select-trac models(Command-trac is different). So if you are in 4 part-time and you build up some drive-train tension from binding, then the spring doesn't have enough force to slip here out of 4wd. It usually slips out a little latter and that is typically with a bang due to the sudden release of tension.
Quick fix is made sure you have a nice straight section of road (100-200 feet) to shift in and out of 4 part-time. This prevents any drive-train binding and allows it to come in and out easily.
Another thing that works sometimes. If you where in part-time and it won't come out. You can tell by it still binding. Then put here into full-time and shift back into 2wd when you a nice strait section. Also, putting here into 4-low and back into 2wd works also.
Also as far as the light is concerned all it tells you is the position of the lever. It does NOT tell you wether you are in 4wd or not. The light can be on and not in 4wd; or the light can be off and you are in 4wd. The light is kind of useless, I know. The computer does not control the transfer-case or 4wd in anyway. There is simply a little transfer case position switch that tells the position of the handle. You can go unplug the little 3-wire switch and the light will never come on, but you can still go into 4wd just fine. The ECU does not control 4wd, all completely manually operated.
Finally, I'm sure you are aware of this but just in case.
Part-time is NOT to be driven on dry roads or anywhere where there is good traction. It WILL bind. I know what the owners manual says, but I would not use it on wet or slippery roads either. Only use it when you really worried about getting stuck or 4-wheeling.
Full-time was really made for wet/slippery/snowy roads. In Full-time you will not have any problems with binding, it will not bang, etc. Just make sure you shift up to full-time in one motion and not stopping in part-time.
In short, use full-time only unless you are stuck or four-wheeling.
4wd does not always in-gage instantly, especailly in select-trac. Need time for the gear to mesh. Normally it does happens instantly though. That is what they always say shift into 4wd before you need it. And in case you where not reading above, don't rely on the light to tell you anything.
Just one clarification on the post above, contrary to UPSLibby there are no disconnect hubs on the liberty. They are always connected.
SUMMARY: Your KJ is not a lemon. Use full-time only, unless you are really stuck or 4-wheeling. Part-time will bind even on wet or slippery roads, so only use it unless you are stuck. If you need to come out of part-time find a nice straight section of road(100-200feet) and shift out of it when moving straight. The 4wd light only tells you the position of the handle, not if you are in 4wd or not. The computer does not control 4wd in anyway. Make sure you shift into 4wd before you need it.
Last edited by Eddo on Sun Mar 05, 2006 2:45 pm, edited 1 time in total.
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