96 Cherokee transfer case issues

G'day all from Aus!

I've been a member since late last year but haven't really gotten around to posting anything up until now. Just wanted to start by saying what a great forum you've got here - dedicated to what recently became my first car!

Anyhows its not all sunshine and daisies unfortunately, my 1996 Cherokee Sport 4.0L Petrol (converted to dual-fuel) is having some issues. Mostly minor and ill get to them if and when i solve this more pressing issue.

I've had the car for over a year now and basically in 2wd the car runs beautifully. Its done about 195000kms (~120000miles i believe) and is probably third hand. The owner once prior to the one i bought it off had it as a company car (Dewalt actually) and I'm pretty sure its seen little if any off road use.

Now what I've noticed as iv become more keen to take my baby off road is that when shifted to 4wd (Low, high, full and part time) I noticed groans that seemingly come from my rear differential and when i put it into a tight corner at slow speed i get awful groans from the front diff also. During the corner the car also rolls about the front axle and the wheel turns by itself slightly from side to side. I think this reads worse than it is but you can imagine that its not a situation I'm particularly fond of!

Also it is very reluctant to disengage 4wd, the light stays on and it can take ages for it to finally feel like its back in 2wd. My technical know how is limited at best but it feels to me that the diff isnt functioning properly at the front, like the two front wheels are trying to turn the same speed while turning...

I can only hope that I've explained it concisely and accurately and that someone out there knows what im dealing with.

Also i've read of somewhat similar situations attributed to transfer case linkage adjustment, is this perhaps all im dealing with? I plan on taking it to a jeep specialist but thought I'd ask about first!

Any help would be greatly appreciated,
Alex.

http://www.naxja.org/forum/showthread.php?t=935844

http://www.naxja.org/forum/showthread.php?t=935379&page=3

Those will give you a bit of infor on your T Case, it sounds to me like its working fine, just needs a bit of a fluid change. If that doesnt help, then i would suggest a linkage adjustment, either by yourself or some one who knows the linkage set up and can do it right.

Also, read through those and you will see various tricks and methods to get it out of 4x4 part time, or into which ever 4x4 you want. I usually just leave mine in full time.

Really appreciate the speedy reply mate, I'm off to bed now but I'll have a read through those links tomorrow at uni. Thanks a bunch mate, hopefully once all this is fixed up ill chat to you lot about the more fun aspects of owning a jeep!

-Alex.

When you say "rolls about the front axle"...are you on pavement when you're in 4 wheel drive? Maybe hard packed dirt? It sounds like you're binding the transfer case, to me. Especially when you say you can't get it out of 4 wheel drive (unless I'm reading it wrong). Have you checked to make sure you have the same gear ratios in your axles?

Edit: You need to look this guy up and find out if he's somewhat local to you. At least we all know he's more local than we are
http://go.jeep-xj.info/

When you say "the wheel turns by itself slightly from side to side", it sounds like the front axle Ujoints could be binding. Try jacking the front end up and trurning the axle all the way to one side. Then rotate a front wheel while looking at a Ujoint behind the hub. If the Ujoint is binding, you should see it (and probably hear it).

I was driving my 2000 XJ with no problems until one day I heard a popping noise on turns in the front. When I pulled the axles, both Ujoints were bound so bad that I had to beat the axle with a 4# deadblow hammer to bend the joint enough to remove the C-clip on the Ujoint caps. There was no earlier indication of a problem.

If you decide to replace an axle Ujoint, don't bother to take the hub nut off. Just remove the axle and bearing assembly together. You can replace the Ujoint without separating the axle from the Ujoint and it will save you time.

Georgia Mike said:

When you say "rolls about the front axle"...are you on pavement when you're in 4 wheel drive? Maybe hard packed dirt?

Click to expand...

I was actually on pavement at the time, only very briefly as i tested switching between 2wd and 4wd. Is this perhaps more likely responsible for most of my symptoms? I'm an idiot i didnt even think that testing on pavement wasnt clever - ill be sure to test 4wd on some softer dirt when i get home.

MoFo said:

When you say "the wheel turns by itself slightly from side to side", it sounds like the front axle Ujoints could be binding. Try jacking the front end up and trurning the axle all the way to one side. Then rotate a front wheel while looking at a Ujoint behind the hub. If the Ujoint is binding, you should see it (and probably hear it).

Click to expand...

Assuming i didnt create that problem for myself by testing on pavement ill be sure to try what you suggest once im able.

Thanks a lot for your responses, already im learning (never heard the term 'binding' before and after a quick google i think iv got the idea). Thanks again, I'll test the 4wd out again when i get home on some softer dirt and hopefully post back the results.

Cheers, Alex.

Update: Okay i feel pretty silly now, having tested the car on looser soil it appears that the majority of my symptoms were due to my testing on pavement. It was still quite difficult to get out of low range but i think im getting the knack to getting it out of full time and high range.

My experience with automatic 4wd is nill so i guess i just wasnt expecting so sever of an impact from driving on pavement - it really was quite worrying. I guess ill check out the fluid levels and keep an eye out for any issues in the future.

Thanks a lot for all your replies! I guess now i've got to ask your advice on the groans im getting from my rear drum. Haha stay tuned for a new thread!

Cheers,
Alex.