Join Date: Sep 1999
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Re: Four-wheel-drive on the fritz
Pull the shift motor off the axle and check to see if the collar and shift fork are ok. Be ready to catch some fluid when you take the motor off but it won't be too much. Check the condition of the shift fork; they are known for weak castings in the early years for both YJs and XJs. Try to move the collar back and forth by hand; if the halfshaft splines don't line up, turn the front driveshaft by hand until they do. If it doesn't move freely, slather a good amount of axle grease on the splines and work the grease under the collar by moving it back and forth. When you put the shift motor back on the tube, make sure the fork rides in the collar center groove. You can use RTV to make a gasket if the orginal one is not reuseable.
While the motor is off the axle, give it the "suck" test again and see if the fork moves back anfd forth. Good Luck!![img]/wwwthreads_images/icons/smile.gif[/img]