Transfer case - Knocking/Rattling Noise From Shifter
NUMBER: 21-010-05GROUP: Transfer Case
DATE: April 23, 2005
THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 02, 2005.
SUBJECT:
Spark Knock Or Powertrain Rattle-Like Sound From Transfer Case Shifter Area
OVERVIEW:
This bulletin involves inspecting for, and if necessary, installing a transfer case shift assembly drain hole grommet.
MODELS:
2003 - 2004 (TJ) Wrangler
NOTE:
This bulletin applies to vehicles equipped with a 42RLE automatic transmission (sales code DG6) and built between March 01, 2003 (MDH 0301XX) and May 01, 2004 (MDH 0501Xx).
SYMPTOM/CONDITION:
The customer may experience a spark knock or powertrain rattle-like sound while driving the vehicle. This sound may occur more frequently when the transmission shifts into 4th gear lockup (overdrive engagement). The source of the sound may be from the center console and/or transfer case shift assembly.
The spark knock or powertrain rattle-like sound may be caused by a drain hole grommet not installed in the bottom of the transfer case shift assembly.
DIAGNOSIS:
1. Inspect for the transfer case shift assembly - drain hole grommet from under the vehicle (Fig. 1).
2. If the customer experiences the above condition, and the drain hole grommet is not installed to the transfer case shift assembly, then perform the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Disconnect and isolate the negative battery cable from the battery.
2. Using a trim stick, or equivalent, remove the cup holder insert, if equipped.
3. On full console models remove the trim disc from the bottom of the cup holder.
4. On mini console models remove the bolt and remove the cup holder (Fig. 2).
5. Remove the automatic transmission shift handle and bezel or remove the manual transmission shift boot from console (do not remove the shift boot from the shifter).
6. Using a trim stick, or equivalent, remove the air bag deactivation switch and disconnect the electrical connector, if equipped.
7. Remove the bolt(s) attaching the console to the floor pan.
8. Apply the parking brake.
9. Shift the transfer case in to the four low A-Lo" position.
10. Shift the transmission to the Low "L" position (2nd gear for manual transmission) and remove the console assembly.
11. Twist and remove the shift bezel light.
12. Install the drain hole grommet to the transfer case shift assembly (Fig. 3).
13. Install the shift bezel light.
14. Install the console assembly. Tighten the attaching bolt(s) to 4 Nm (35 in. lbs.).
15. Connect the air bag deactivation switch and connector, if equipped.
16. Install the automatic transmission shift bezel and handle to the console.
17. Install the manual transmission shift boot to the console.
18. Install the cup holder and trim disc.
19. Shift automatic transmission to the PARK "P" position.
20. Shift the transfer case level to the A Hi" position.
21. Connect the negative battery cable to the battery. Set clock to the correct time, if equipped.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.