Service 4wd Light

It’s time for Jeep to just sack up and admit there is a problem and come up with a real solution but I’m not going to hold my breath.
 
Thinking about a Dana 60 in the rear and either program (Tazer), gut, or replace the TC. Might as well lift and run 37s at that point.

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@~38k the transfer case actuator finally failed
Mentioned prior two or three times in this thread by others as the root issue
Should be about a 2 day turnaround at the shop.
Thanks & hats off to the service team @ St. Augustine FL Dodge/Jeep
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I had the same problem with the warning lights, but my cause was different. Turned out that under extreme droop of the right rear wheel, the ABS sensor line was stretched around the rear sway bar, end lin, and a wire broke internal to the harness. Took a while to figure out, but was a straightforward and easy fix.
 
At the dealer right now. Service rep says Jeep opened a star case after we showed up. The dealer tech was contacted by Jeep engineers to troubleshoot. Got the service 4WD twice now on the 2022 392 (built August 22), both times on hot days after restarting following long drives. Never had a tazer, only minor mods. After first incident (service 4WD light, front feels like 4LO is engaged), changed the fluid. Took a sample and it looked fine. Checked level originally when it was new and it was fine. Didn't see any loose fuses or obvious wiring harness issues. Most recent incident was at 6k miles. Will update when we know more. Feel like we're driving a time bomb. I think we may all be. This is my wife's Jeep and it is babied. Most extreme offroading has been a few forest roads. If it can happen to her Jeep, then it could happen to anyone.

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SCARd4Life said:
At the dealer right now. Service rep says Jeep opened a star case after we showed up. The dealer tech was contacted by Jeep engineers to troubleshoot. Got the service 4WD twice now on the 2022 392 (built August 22), both times on hot days after restarting following long drives. Never had a tazer, only minor mods. After first incident (service 4WD light, front feels like 4LO is engaged), changed the fluid. Took a sample and it looked fine. Checked level originally when it was new and it was fine. Didn't see any loose fuses or obvious wiring harness issues. Most recent incident was at 6k miles. Will update when we know more. Feel like we're driving a time bomb. I think we may all be. This is my wife's Jeep and it is babied. Most extreme offroading has been a few forest roads. If it can happen to her Jeep, then it could happen to anyone.

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My 2022 built in August had the same problem. It was the transfer case electric motor on the back of the transfer case. Very simple fix. It’s 105 here now and no issues at all since they replaced it.
 
Bocephus said:
Happened to me (service 4x4) at dealer now. Apparently threw a u1440 code, among others. They’re not sure what’s up yet, but “replacement of transfer case” was mentioned. Pretty sure that’s not happening. It came on only in 4low and didn’t return the next day when I put in 4low for several miles. Also having trouble getting the sway bar to connect / disconnect, which dealership says may be related, which doesn’t seem to make sense.
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I had both issues. Serv4WD and Sway Bar Disconnect.
SERV4WD ended up being transfer case after 15 months of fighting with them and dealer trying wire harness overlays, transfer case motor switch, control module etc.
Sway Bar Disconnect was harness melt due to being too close to the exhaust manifold. Fixed pretty quickly.
 
GuruMan, You are correct and this is common. I dont know why they cant check this early on in the diagnostic process.
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What will happen if you unplug the clutch pack motor?

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Finally got some resolution on the Error code. Turns out the clutches in the transfer case are burned....new TC on order....5 days out....
I wonder what cause the clutches to burn?
 
My 392 (12,000 mi.) was towed to dealer on 7/31 with service 4wd light and stiff turning. Got it back today with new transfer case assembly complete. Seems fine now but time will tell. They got the new transfer case in 3 days but dealer service was backed up till 8/14.
Going to put it through it's paces tomorrow and see if it holds up.
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Hokie Eng said:
My 392 (12,000 mi.) was towed to dealer on 7/31 with service 4wd light and stiff turning. Got it back today with new transfer case assembly complete. Seems fine now but time will tell. They got the new transfer case in 3 days but dealer service was backed up till 8/14.
Going to put it through it's paces tomorrow and see if it holds up.
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Mine was done in June. No problems so far.
 
Hokie Eng said:
That's encouraging. Hopefully they are replacing these units with ones that have the flaw fixed. My perception this is a fairly common problem. Odd too because I have in no way beat on mine. Honestly it has been pretty babied.
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Might as well ask. Anyone grenade their second transfer case?
 
Hokie Eng said:
That's encouraging. Hopefully they are replacing these units with ones that have the flaw fixed. My perception this is a fairly common problem. Odd too because I have in no way beat on mine. Honestly it has been pretty babied.
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Not likely they are doing anything. Problems with this t-case have been going on for 10 years. It is over engineered for a Jeep. They have been replacing parts or whole t-cases since 2011 when it was introduced.
 
I don't have a 392 yet and finding this thread is not giving me good feelings. I am not sure what the problem is but if I pay $100K for one and the TC fails and sits at the dealer for weeks I am going to be more than upset. Looks like there is no real fix for this other than a new TC. Is the new one any different? You don't build a $100K jeep with a known failure. My 22 Gladiator has not had a problem. I am not going to buy a 392 just to replace the TC and a D60 just to make it right. If the drivetrain can't handle the 392 then we have a bigger problem. I'll just keep my JT.
 
I see your point.
It seems to be back to the way it was and it is performing normally although I have not stressed it and never did to be honest. I kinda baby this thing except for the occassional rip. There are some owners that beat the hell out of theirs and have never has an issue with the TC.
I was not aware of this problem before I bought my 392 and now that I did experience it , I have done a lot of research during the three week wait to get it back and note that the TC failure does happen but I would not say that it is necessarily "often". Just was a pain to wait 3 weeks but that is because of the dealer being backed up because they need mechanics desperately. They got the parts in 4 days. It just sat wqiting to be repaired. I will say this, it is a brand new TC and not a reman.
Additionally, they seem to fail due to several issues with it as the dealer said their are several error codes it can throw. Mine was "transfer case motor blocked." They can fail by clutches burn out, etc. Either way and due to the failure rate for the past 10 years (yes it is a 10 year old design with I assume minor improvements along the way) I would have thought it would have been reengineered and/or switch suppliers although Magna Power is typically putting out a high level component. Also, there are hundreds of thousands of these exact T cases in use so that also increases odds af failures.
Even if I was aware of this potential I would have bought it anyway. Other than this one event after 12,000 miles my 392 has been flawless and I absolutely love it and am thinking about upgrading to the 2023 with the new dash.
 
Hokie Eng said:
Maybe just negotiate as part of your purchase when you buy it that if you do have this problem that service gives you a priority and give you a Rubicon loaner during the fix. My only beef is it took 3 weeks. That is unacceptable and I let Stellantis know that in so many words. They would do that.
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