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Old May 8th, 2012, 10:32 AM   #1
BATLWGN
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NP231 popping out of 4WD

Just like the title says...

92 YJ with the 4 banger with 95K miles.......Just to make sure, I pulled the rear drivesaft and took it up and down the driveway. Under load it will pop out of both 4HI and 4LO. If you move it to 2WD and back into 4WD it re-rengages, but when under a load... POP. Although I can still back up after it pops, so I loose 4WD going forward, but not reverse.

I was told it might be an adjustment, but it is stock and nothing in the linkage looked out of place there. Was also told it might be the plastic 'feet' on the mode fork that fell off or broke and wasn't it fully engage. So i pulled the back half off the case and everything looks to be in really good shape.

This was mostly used as a summer beach toy for most of it's life so the chain looks good and I am not seeing any other obvious wear or problems. The only thing I noticed it when pulling the rear cover, i saw that the transfer csae skid was rusted out at the mount point and allowing the case to droop more than normal.

After pulling the back cover and seeing how the shift linkage cam operates the forks, I don't see how it would pop out of both HI and LO. I can see an adjustment affecting not engaging HI, but by the time the floor lever is pulled back into LO, the cam in the T-case is definately rotated enough to be engage.

Am I wrong on this thinking? Any suggestions since I am not sure where to turn next?

Last edited by BATLWGN; May 8th, 2012 at 11:26 AM.
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Old May 8th, 2012, 10:49 AM   #2
cwk33041
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I would check the vacuum actuator on the front axle. I had the same issue with my Jeep YJ. To be clear the actual transfer case jumping back to 2 wheel drive or is not staying engaged in 4wd?

This is what I am talking about (it is located on the front axle):




*edit: I would also check all the vacuum lines. and possibly the vacuum switch located on the top of the transfer case:

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Old May 8th, 2012, 11:22 AM   #3
BATLWGN
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Thanks for that..... but I forgot to mention, the front CAD is locked in the engaged position. And that vacuum switch only sends the vacuum signal to the CAD, correct?

And it is not staying engaged in 4WD. I physically move it back up to 2WD and then back into 4WD to re-engage it. Edited for clarity.

Last edited by BATLWGN; May 8th, 2012 at 11:26 AM.
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