Question about 1991 Jeep Wrangler

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91 Jeep Wrangler Sahara, 2WD won't engage, 4WD is fine!

Need some help to point me in the right direction.
Totally stock Sahara, 4L motor, 5 speed manual tranny, 180K miles.
My Sahara won't engage 2WD!... My wife was driving along and clunk! The normal 2 wheel drive stopped working. It was making a kind or "rattleing sound" when decelerating in gear, like slowing for a stop light.
I went to the rescue, and she was right... when you put it into gear in 2WD it don't go!... it's like the transfer case is in Neutral.
BUT, if you switch it into 4WD Lo or 4WD Hi, the car will drive just fine.
I appreciate your help!
O yea, and my Chilton's wasn't much help.

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Check to see if front drive shaft is locked in by spinning it by hand, if it is there is a sensor on top of the tranfer case that has the vac lines connected to it. On the bottom of the sensor there is a ball. If the ball gets stuck open the vac stays on and the front end stays engaged no matter if your in 2 or 4. The sensor is like 22 dollars from chrysler.

Posted on Jun 26, 2009

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It sounds like your driveline to the rear wheels is broken. Could be transfer case output shaft to the rear wheels has broken. Try disconnecting the rear drive shaft and see if you can turn it by hand with the transfer case engaged in 2WD. If you can turn it while the Sahara is in gear, the output shaft is no longer connected to the engine for some reason.

Posted on Dec 29, 2008

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2x4 Hi is for normal driving in most weather and anytime you are driving over 50mph.

4x4 HI is for getting you unstuck from mud or snow and can be used up to 50mph but is not recommended for much faster. It is only designed to get you moving and unstuck, it will NOT make it any safer to drive faster on slick surfaces like rain, snow, or ice. Always drive slower on these kinds of surfaces.

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First, make sure you are parked and the wheels are not moving. Put the main gear shift (5-speed) into Neutral, hold down the clutch and move the selector from 2x4 to 4x4 by first pulling the shifter to the side then moving it up or down. Some jeeps (especially older ones) may have a wheel lock on the outside of the wheel hub (AKA hub lock). This must be in the "LOCK" position for 4x4 and "UNLOCK" for normal 2x4 driving. Make sure it is fully engaged in the slot before shifting into 1st. Then you can drive normally, following the guidelines above.

The regular 5-speed transmission will shift just the same as before but you will notice that the jeep will drive much slower in 4x4 lo and it will have much more torque for those really sticky situations.

Good luck! Have fun! And if you do plan on doing some real 4x4'in or mud boggin' make sure you buy a winch for the front of your jeep or bring a friend who has a winch on their truck to get you unstuck from the worst of the worst! Don't forget to rate!

P.S. if you have problems with one or more 4x4 settings you can always shift back to 2x4. Make sure that if you are driving on the highway or in normal driving conditions, you are always in 2x4.

P.P.S. If you are near the Columbia, MO area send me a PM, I'd love to find some new friends to do some 4x4 driving with in the area so I can get back into the sport. I miss it.

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There are a number of things I've learned to persuade a stubborn xfer case to shift.

Try mixing these :
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Let me know how it turns out.
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