Transfer Case Shifter rattle

(1993 XJ Sport, 4.0L)

It has been a while since I've had my Jeep in 4WD (sorry! ), but I used it today to get out of a snow-surrounded parking space. I put the transmission in N, shifted to 4-Hi, put the transmission in drive, got myself out of the snow, transmission back to N, TC back to 2WD, tranny back to D and on my merry way (btw, can you shift the transfer case while the transmission is in gear?).

Anyways, after driving for a bit I started to notice a soft rattle coming from the transfer case shifter. I also noticed it had some play in it. I could push it "further" than the 2WD setting, if that makes any sense, but it'd spring back to where it was setting. I could also pull back on it a little bit too, and it'd spring back.

I notice the rattle at idle and when going over bumps, snow, etc. I notice it a lot less if I push the TC shifter "forward" while driving.

My searching the forum tells me that its a relatively inexpensive fix if it is the plastic bushings, is this correct?

My main question is that is this a driveable issue? I'm not so much concerned about the noise but rather the potential that something is wearing down at an abnormal rate. As I said, its been a while since I even put it in 4WD, and after putting it back and noticing this rattle and especially the play in the shifter, I can't recall if it did this before...

Thanks in advance!

sounds like your shifter linkage is just loose. Mine rattles all the time.

Hey MJCfromCT for your shifting into 4wd. You can shift on the Fly into 4HI but you have to be stoped and trans into Netural and be stoped to shift into 4LO. I would not be moving or spinning when going into 4lo must be stopped. and for 4hi moving slower thant 40mph

Thanks for the clarification derrickdrew17

ty20404,

As long as its a driveable issue, I won't mind. I'd like my Jeep to last as long as possible.

Mine does the same exact thing. I would also like to know how to fix it. Other than my self defense club wedged in there to keep it pushed forward...

here ya go. common problem, easy fix.:spin1:

There was a TSB for XJ, TJ, and ZJ T-Case shifter ratteling it had involved installing a new shifter support bearing and boot as well as all new grommets.

NO: 21-09-98
SUBJECT: Transfer Case Shifter Noise
DATE: Jul. 31, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 21-02-97 REV. A, DATED, JULY 11, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILE AND NOTE IN THE 1997 BOUND TECHNICAL SERVICE BULLETIN MANUAL, PUBLICATION NUMBER 81-699-98004. THE BULLETIN ADDS MODELS AND ADDITIONAL PARTS. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**.

SYMPTOM/CONDITION:
A thumping or creaking noise may be heard coming from the transmission tunnel area on acceleration or while driving over bumpy roads.

DIAGNOSIS:
Road test the vehicle, if the noise is present and there are no worn or damaged parts relating to the transfer case shift mechanism, perform the Repair Procedure.

PARTS REQUIRED:
Qty Part No. Description
1 04886481AA Repair Kit, Transfer Case Shifter(ZJ/ZG)
**1 05014148AA Repair Kit, Transfer Case Shifter(TJ/XJ)**


REPAIR PROCEDURE:
This bulletin involves installing a transfer case shifter repair kit.

Disconnect the shift rods from the torque shaft.
Remove the torque shaft by prying the shaft out of the green torque shaft bushing in the transmission bracket. (Refer to Figure 1) Install new bushings on the torque shaft for XJ and TJ.
Remove the bronze bushing/retainer and rubber gasket from the body bracket.
Remove the green torque shaft bushing from the transmission bracket and install the new bushing supplied in the kit.
Insert the new gasket into the body bracket.
Install the bronze bushing/retainer and tightening the screws to 5 N•m (45 in. lbs.).
**NOTE: TJ AND XJ MODELS USE THE ORIGINAL TORQUE SHAFT WITH THE NEW PARTS SUPPLIED IN THE XJ/TJ KIT. ZJ/ZG REQUIRE REPLACEMENT OF THE TORQUE SHAFT WHICH IS SUPPLIED IN THE ZJ/ZG KIT.**

Slide the boot on to the torque shaft and apply multipurpose grease ( MOPAR p/n 04318063 or equivalent) to the area that the bronze bushing will contact.
Install the torque shaft and seat the boot on the bushing retainer flange.
Connect the transfer case shift linkage and adjust as necessary.
POLICY:
Reimbursable within the provisions of the warranty.

I thought this TSB was for 1995+ XJ's? I have a 1993.

TSB with picture...

http://home.sc.rr.com/janet/TSB/21-09-98.htm

MJCfromCT said:

I thought this TSB was for 1995+ XJ's? I have a 1993.

Click to expand...

similiar setup (just like the rest of the drivetrain)