2021-2023 Jeep Wrangler & Gladiator Transfer Case Grinding

Owners of 2021-2023 Jeep Wrangler and Gladiator models equipped with a Front Axle Disconnect (FAD) system might encounter a specific issue with their vehicle's 4WD. This concern, detailed in STAR Online Publication S2403000002, involves a noticeable grinding or gear clash noise emanating from the transfer case.

This Jeep Wrangler transfer case grinding issue typically occurs when the vehicle attempts to engage 4WD at speeds exceeding 5 mph (8 kph). It's important to note that this document specifically addresses 4WD systems that utilize a Front Axle Disconnect (FAD).

Symptoms

The primary symptom is a distinct grinding or gear clash noise originating from the transfer case. This noise is most apparent when the driver attempts to engage the 4WD system while the vehicle is moving above 5 mph. Some owners have reported that this noise began shortly after their transfer case was replaced for a different issue.

Diagnosis and Trigger Conditions

If you experience a Jeep Wrangler transfer case grinding noise under the described conditions, the root cause might be an incorrectly installed transfer case. Technicians investigating this issue should first check the part tag on the installed transfer case to identify its part number. It is also crucial to confirm if the vehicle is equipped with a Front Axle Disconnect (FAD) system, as this bulletin applies exclusively to FAD-equipped vehicles.

Root Cause of the Grinding Noise

The grinding or gear clash noise is often a result of an incorrect transfer case being installed during a prior service. Specifically, if the transfer case part number is 68642951AA and the vehicle has a FAD system, then the wrong part has been fitted. The transfer case with part number 68642951AA is designed only for vehicles with a FAD delete 4WD system.

This installation error stemmed from an issue in the parts catalog, where part number 68240441AC was incorrectly superseded by the incorrect 68642951AA. This catalog error is expected to be corrected soon.

Repair Procedure Summary

To resolve the Jeep Wrangler transfer case grinding issue, the incorrect transfer case must be replaced. If the vehicle has a FAD system and the installed transfer case is part number 68642951AA, it should be removed and replaced with the correct transfer case, part number 68240441AC.

Required Parts

• Incorrect Transfer Case (to be replaced): 68642951AA
• Correct Transfer Case (for replacement): 68240441AC

Important Warnings

This document, STAR Online Publication S2403000002, serves as a record of past experiences and does not authorize warranty repairs. It is a communication intended to provide information based on known cases. The parts catalog error that led to the incorrect part supersession is expected to be corrected in the near future.

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Source: NHTSA ID: 11006240