Transfer Case Stuck
My truck seems to be stuck in four wheel drive even though my switch is in 2 wheel drive. When driving it sounds like it is stuck in. I have tried to stop and switch between all ranges in neutral it does not work.
Try out this solutions:
check the fuse. There are three main things that will blow the fuse; the front axle actuator, the encoder motor on the transfer case or a mechanical problem in the transfer case. First unplug the actuator and see if the fuse blows. If not the actuator is bad, If the fuse blows, unplug the motor on the transfer case. If the fuse does not blow with the motor unplugged, but does with it connected, remove the motor from the case and try again. If it still blows the fuse, the motor is likely bad. If the fuse does not blow with the motor out of the transfer case, the problem is more likely internal to the case. If it binds internally, the motor will pull too many amps and blow the fuse.
Check the fuse box:
turn the vehicle on and have 2wd selected and get under the truck and tap on the shift motor on the transfer case with a small hammer or something see if it will pop out. ive seen alot of motors go bad and if you hit them they will go to working again, for a little while anyways. it could be a control issue or internal transfer case issue. but hitting the motor is best thing to start with.
get the axle removed the truck will run regular just without the 4 wheel drive
if its in 4x4 low removing front shaft wont help. its ran by vacuum located on the front axle and runs up firewall on the passenger side under the hood. try putting it in neutral click to 4x4 hi and then back up about 100ft if that don't work try to take a screw driver to the lever on the axle to kinda help it out in shifting to 2wd pretty simple when you see it. let me know hope this helps.
99 Tahoe stuck in 4 wheel drive low
small electric actuator on the Front Transfer Case .. what happens is that
unit will Freeze Up in very cold weather .. it is up under the vehicle
on the driver's side and is controlled by the lever on the floor of the cab.
4WD is not the same as Low Range.
To get out of Low Range, you typically have to be in Neutral or Park, switch to 4WD High or to 2WD, and then back up several feet. That has been my experience with every electronic transfer case I've used, though I will admit that I have not driven a Tahoe. That's how it worked on a Suburban though.
If it is a manual transmission vehicle, shift the transmission into neutral, hold the clutch in, and then disengage the 4x4. If it is an automatic, put it into neutral, then disengage the 4x4. A vehicle of that age, if it has automatic locking hubs, will need to be driven in a straight line in reverse about 50 feet to completely disengage the hubs. When you stop from your reverse drive, hit the brakes a little harder than normal; this helps to "unstick" hubs sometime. If you have manual hubs, you need to disengage them on your wheel hub.
More then likely it's one of two things - the TC (transfer case) linkage is loose or broke and is not dis-engaging 4wd or the VACCUM lines that control your front axle is loose or broken.
Contrary to what was mentioned earlier you do have a vaccum line that is activated when you engage 4wd. Inside your front axle are technically three axle shafts - 1 on the drivers side and TWO on the passenger side. When you engage 4wd it activates the vaccum that powers the motor that moves the fork that engages the two passenger side axle shafts. If the vaccum lines are broke or leaking then it will not engage/disengage the two shafts and the vehicle will act in a manner in which you're describing.
Likewise if the TC linkage is not functiong properly it will not engage/disengage the 4wd system. Check out the link below and make sure you go the YJ (Jeep Wrangler from 1987-1995 - the TJ was from 1997-2006 - Jeep did not have a 1996 Wrangler) Technical section and look around - use the search function to find your answer but if you can't find it don't hesitate to ask.
EDIT: You do not have "auto" locking hubs. You have direct drive (not sure on the exact terminology) hubs that are ALWAYS connected. That's what the vaccum disconnect does only it disconnects the two passenger side axle shafts. And there is no reason to jack your vehicle in the air or any thing like that. I'm 99.9% positive it's the vaccum lines. It's very easy to check the linkage - have someone shift the vehicle in and out of 4wd while you look underneath. There will be a rod that connects the shifter to a mechanism attached to the body that has another rod that is connected to the TC. You should be able to tell if one of them is not moving. I have also included a link below (the second one) that will describe how to adjust this linkage. It's for a TJ but the linkage is the same as your YJ.
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