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ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: Rez Zuki 87 on March 04, 2008, 04:58:15 PM

Title: 4wd low keeps popping out
Post by: Rez Zuki 87 on March 04, 2008, 04:58:15 PM

New owner of a 87 Sami.  It has an annoying habit of popping out of 4wd low when it hits any bumps.  4wd hi and 2wd works fine.  I have changed the transfer case shifter sheet with a brass one from zuksoffroad.com.  I also did the fix for the sloppy transmission shifter.  Some advice - if the broken bolt is still partly screwed when you take the shifter out if transmission, stuff the hole with a clean rag, make sure you don't push the rag all the way down inside.  It will help keep the broken bolt from falling into the transmission when you punch it out. 
Anyway, the transmission and transfer case shift better, but it still pops out of 4wd low.  I don't mind taking the transfer apart to fix it, but it would be the first time I would be doing it.  Would it be better to fix it or just buy another one?  I'm on a limited budget(3 kids) and any help will be appreciated.

Title: Re: 4wd low keeps popping out
Post by: sanjuansheriff on March 04, 2008, 05:18:35 PM

Rez,
I just rebuilt my samurai transmission for the first time.... At first it seems intimidating but all made sense once I got started it was a snap. If I remember a rebuild kit for the transfer case is about $80/90... A rebuilt T-case is $600
plus shipping and the cost of returning the core. I would vote for doing it yourself.

Dennis

Title: Re: 4wd low keeps popping out
Post by: idaholwb on March 04, 2008, 08:28:50 PM

 If you are having a problem with the transfercase popping out of low after fixing the shifter sheet, try replacing your transfercase mounting arms with heavy duty ones. More than likely you have a bent one that is affecting the alignment of the intermediate driveline causing issues that make it pop out. It would only be an issue in low range.

Title: Re: 4wd low keeps popping out
Post by: zuksofhazzard on March 05, 2008, 11:30:50 AM

I agree, your T-case mounting arms could be bent, broken, twisted or even as simple as loose bolts.

Definately check those before you spend any money.

You might want to make sure that your T-case shift boot is re-installed correctly. It could be keeping it from fully engaging when you make your selection.

Check your carpet around the opening too. It could restrict the throw of the shifter.

Title: Re: 4wd low keeps popping out
Post by: mic on March 05, 2008, 11:54:38 AM

Do you have a body lift? If so the boot could be too tight causing it to pop out. I'd check the boot any way. Good luck.

Title: Re: 4wd low keeps popping out
Post by: Rez Zuki 87 on March 05, 2008, 05:26:19 PM

Thanks for the info.  I'll check the mounting arms first before I buy any parts.  I don't think it has a body lift, but I'll check.  What size should the standard body mounts be?  I'll check the boot and carpet, too. 

Hey, San Juan, are you around Farmington, NM?  If you are, where are the best places to get parts?

Title: Re: 4wd low keeps popping out
Post by: sanjuansheriff on March 05, 2008, 06:22:25 PM

Hey Rez,
It's all coming together.... First off no I am from San Juan County in Washington state... But I have been to your neck of the woods... The rez and Chaco canyon which as you know are also in a San Juan County. That is a great place for a Samurai. My family and I will be returning to Chaco next February on a extended road trip.

Take care,
Dennis

Title: Re: 4wd low keeps popping out
Post by: phloop on March 05, 2008, 07:08:13 PM

Also check the frame mounts that the T/C arms bolt too, they may be tweaked a little also. As for a body lift the stock mounts are just thick rubber kinda like conveour belting, no pucks or blocks.