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ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: kickscrawler91 on January 20, 2008, 01:08:32 AM

Title: 95 sidekick, 4 lo popping out of gear!!!
Post by: kickscrawler91 on January 20, 2008, 01:08:32 AM

When I am in 4 lo my transfer case will just pop in to neutral at random times, under acceleration, at idol, and coast. Does anyone have any ideas? I am waiting for it to pop out during some serious wheeling.  :o

Title: Re: 95 sidekick, 4 lo popping out of gear!!!
Post by: museboy07 on January 20, 2008, 07:40:17 AM

I have that same problem on my 94 track.  I figured out the problem by taking the stock t-case boot out and making my own.  It seems that the stock boot was being used as a rubber band and when i tried to shove it into 4lo  it just popped right back out.  But after i made a custom boot it hasn't happened since.

Title: Re: 95 sidekick, 4 lo popping out of gear!!!
Post by: locjaw on January 20, 2008, 09:43:21 AM

body flex as well as the boot can make them pop. even if it looks like you have enough clearence , you may not

Title: Re: 95 sidekick, 4 lo popping out of gear!!!
Post by: KickTurn on January 21, 2008, 09:01:22 AM

I have the same problem on my 95 sidekick, and it's not the boot-- I ran it with the boot removed, and it still popped out of 4-low.  The shifter doesn't contact the floor cutout, and I've changed the tranny bushings.  I pulled the transfer case and took it to a good tranny/transfer case shop, and they haven't found any issues with the case itself.  I'm as mystified as kickscrawler91.

Title: Re: 95 sidekick, 4 lo popping out of gear!!!
Post by: KickTurn on January 21, 2008, 03:54:28 PM

locjaw, if the problem is body flex, what can be done about it?

Title: Re: 95 sidekick, 4 lo popping out of gear!!!
Post by: Drone637 on January 21, 2008, 07:27:09 PM

Trim the body so it no longer flexes into the shifter.  :)