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Rebuilt Sammy transfer case won't shift to 2 wd

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Offline daddyizzle

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Rebuilt Sammy transfer case won't shift to 2 wd
« on: October 13, 2007, 04:29:17 PM »
I rebuilt the transfer case and was bench testing for shifting. I can shift into 4 lo, 4 hi, and nuetral. When I shift it to where 2wd should be, it feels like it shifts properly but when I turn the input, the front output is still locked in with the input . Am I missing something here? I know I have all the little ballls and springs in place. Maybe once it's mounted on the vehicle it will work right because I will be able to shift it easier being mounted? I just don't understand this.... :sleepy: :sleepy: ??? ??? ???

-Adam
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Offline mrfuelish

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Re: Rebuilt Sammy transfer case won't shift to 2 wd
« Reply #1 on: October 14, 2007, 12:27:54 PM »
It should work on the bench, maybe you have the coupler on backwards for the 2wd-4wd ?, take the front output section off and see if you can look in there and see what is going on. also check your shifter first make sure you have the side to side shifting working(left to right with the stick)or you might just not have it linned up when your putting the shifter in.
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burke

Re: Rebuilt Sammy transfer case won't shift to 2 wd
« Reply #2 on: October 14, 2007, 12:42:47 PM »
When you rebuild you sometimes need to shim the output shaft so that the positioning of the gears is correct.  Even though you shift into 2wd the coupler may not be clearing the 4wd drive gears.  2wd is the middle position and I would suspect the most sensitive to this clearance.

I am just now rebuilding mine and wondering if I am going to have the same problem.  I do not have a depth gauge to make the measurements that the service manual says I should to calculate the proper shim height.

By the way, know where I can buy a new set of speedometer gears (bot the big and the small)?  I broke teeth of of both of mine :'(
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Offline mrfuelish

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Re: Rebuilt Sammy transfer case won't shift to 2 wd
« Reply #3 on: October 14, 2007, 02:47:18 PM »
You might still be able to download the instructions from petroworks, I have had mine appart a couple of times I just put the case halves together without the gasket and used a feeler gauge where the case halves meet to get the correct shim size.
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1987,1988,1988,1990 samurai's,  1953 m38a1,  1996 x-90,blue.1996 x-90 red.1994 2 door tracker.   only Dead Fish go with the flow.                No Hairy Nosed Wombats were ran over on the trail today.       My ZUK is Xenophobic.
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Offline daddyizzle

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Re: Rebuilt Sammy transfer case won't shift to 2 wd
« Reply #4 on: October 14, 2007, 04:22:13 PM »
Quote from: mrfuelish on October 14, 2007, 12:27:54 PM
It should work on the bench, maybe you have the coupler on backwards for the 2wd-4wd ?, take the front output section off and see if you can look in there and see what is going on. also check your shifter first make sure you have the side to side shifting working(left to right with the stick)or you might just not have it linned up when your putting the shifter in.

I'll check that coupler. I could swear it looked the same from either side but maybe I'm thinking of a different part.

I think Petro or maybe it was Hawk told me that I could use the old shims because nothing should have changed. If it's true that you have to change shim sizes when you rebuild, how come the rebuild kits don't come with a small shim assortment?

Dennis, do you know what the link is for the instructions? It sounds like your telling me to put the two halves together and use a feeler gauge between the halves to determine the shim size based on the gap between the halves. What do I use for a shims? When you use shims, are you talking about the really thin washer that is the same diameter as one of the bearings? This is getting kind of technical for me. I guess it would help if I saw someone rebuild one that actually knew what they were doing so I would know what to look for. 

Maybe I better just stick with the transmission rebuilds. I had better luck with them.  :-\ :-\

-Adam
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86 Samurai Tin-Top stock with a Harley 44 sidedraft carb
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Offline mrfuelish

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Re: Rebuilt Sammy transfer case won't shift to 2 wd
« Reply #5 on: October 14, 2007, 08:40:06 PM »
Yep you got it, it's not hard to do,petro has a real good set of instructions with really good pictures maybe they could send them to you, do not remember how my friend got his? maybe with his gear set, I would get a friend to help you hold the case halves together so that they are streight when you use the feeler gauges and im guessing that you need about .006 more than the thickness of the gasket(could be wrong though they might have a preload and use less), they also come in diffrent colors and thickne's, I would have petro send you a set of shims with the instructions to save you some time and maybe another gasket just incase, I think if you where to put in new ball bearings it might change things a little, I ended up using my old bearings and shim's.
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1987,1988,1988,1990 samurai's,  1953 m38a1,  1996 x-90,blue.1996 x-90 red.1994 2 door tracker.   only Dead Fish go with the flow.                No Hairy Nosed Wombats were ran over on the trail today.       My ZUK is Xenophobic.
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Offline daddyizzle

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Re: Rebuilt Sammy transfer case (It shifts to 2wd but turns a little hard)
« Reply #6 on: October 15, 2007, 03:23:31 PM »
I just went out and did a little inspection. I checked to make sure the shifter was in to the "square" all the way so it could shift properly. Double checked and still won't go to 2wd. I pulled the front case off and inspected. front output turns freely so I put it back on and tried turning the front output. The shift levers were set for 2wd. It turns free so it's working. Then I put the case back on and it still turns free. I tighten a couple bolts and I noticed that it was tied up. I grabbed the front output shaft more firmly and it will turn free but there is alot of drag on it and I mean alot. I think its locking up against the shift collar or the gear that it locks against (for lack of a name to call it). It's almost like if I put 2 or three gaskets on it between the front case and main case it would give enough space to where they wouldn't bind.

I wonder if I put the shim on the output rear shaft on the end by the bearing. ??? ??? I guess when I have more time in a day or two  I'll open it up and see if that's the case. I was putting it back together mostly by memory. I better grab my pages I printed out of the fsm and see if it tells me something I've overlooked.

-Adam
« Last Edit: October 21, 2007, 04:44:22 PM by daddyizzle »
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Offline daddyizzle

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Re: Rebuilt Sammy transfer case won't shift to 2 wd
« Reply #7 on: October 21, 2007, 04:57:49 PM »
I took it a part again and did an careful inspection. Here is what I found. The shim was where it belonged  in fact everything was put back right. I had an extra output shaft so I stuck it in the end of the shaft where it goes and it was a little easier to turn until I put it in further and then harder. Upon inspection, it appears a bunged up the opening a little when I pulled the the hub off the output rear shaft. It looks like there is a small bearing in there but I can't get it out. I'll try again when I get a chance. Its where the front output shaft goes into the rear output shaft. I had a gear puller to pull the hub off and I think it pressed the bearing into the inside of the rear output shaft where the two go together if that makes sense. It turns but not smoothly so I think it will cause a whine.

-Adam
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If all criminals were behind bars, there would be no one left to patrol the streets.

86 Samurai Tin-Top stock with a Harley 44 sidedraft carb
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