ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Technical Discussion - Performance / Modify => Topic started by: forman621 on August 22, 2010, 10:24:58 PM
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The transfer case is grinding in all gears even low. i put it in 1st gear and it just freakin grinds like hell.:( It is a 4.16:1 gearing.
what could be grinding in all gearing, except low range!!!!
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??? T-case doesn't have a first, but the trans does.
Grinding trying to put it in gear or after it's in gear it
makes grinding noise?
Not grinding in low range ? T-case in low range or trans in
first gear.
Sorry but your post is a little mixed up, I'm trying to 1st figure
out if you know the difference between the t-case and the transmission
and 2nd if the problem is in the trans or the T-case.
Wild
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Ok that did sound pretty bad.
So the problem started when i was driving down an old highway doing about 40 mph in 4th gear and the transfer case was in 2wd. It just started grinding terribly out of nowhere. and i took it out of gear and put the clutch in and i put it back in 4th gear and i t was fine. it also did it in the rest of the gears. it had just gotten worse to where i could not get going in 1st without it grinding. it also grinds in FOUR HIGH but 4 LOW. so hopefully that is a better understood.
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uhhhh.........sure :-X
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OK lets start with the basics, have you checked the oil in both trans and T-case?
you might want to dump the oil in both and see if there are metal chunks in the
oil or on the magnet in the plug
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yeah i drained the fluid out of the t-case and there was quite a bit of water in it and also some little metel shavings on the magnetic drain plug. so i will tear into it and check everything out. maybe replace the bearings and clean the case out.
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Ya, I bet there are bad bearings in there too and there
might be galling on the gear faces too.
You should drain the trans also, might be water in there too
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ok yeah that is a great idea. i should check that. but the vent hole on the t- case didnt have a hose coming off the top of it.
i am going to buy that kit from trail-gear.com to replace all the bearings. and buy new t-case mounts.
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Ya, you want the t-case and the trans, as well as
both axles to be fitted with tall breather lines to
keep the water a crud from getting in
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i got the transfer case taken all apart and i think the syncros for the input shaft is the part that is grinding. but i didnt get the t-case to grind in 4low so i cant figure which part is grinding. i checked the bearings at they all turn smooth. the only thing i found kind of wrong, was the input shift thing, shows that it was grinding . what do you think
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The T-case does not have syncros, are you talking about the transmission?
There is a engagement dog in the T-case, I had one wear out, and it would
cause the T-case to pop out of low when I was wheeling, it got so bad I
would put a bungee cord on it to hold it in.
Wild
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i am talking about the t case, and yes mine is also popping out of 4 low. which shift fork is used to engage 4low, i see the one at the input shat and the one in the main case. the one for the input shaft i cant get to slide up and down, just wondering if that could be the problem, because i did notice that the teeth on both sides of the shift sleeve were worn down. i didnt see anything else wrong with it. seems like it is in pretty good shape still.
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The one in the front at the input is the high/low shift fork,
the one in the back is 2-4WD and if the front won't move
that is a problem.
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i cant figure out why it wont unless it got jammed in there. there is a small snap ring on the rod of the top shift fork that is not flush with bore, just wondering if it is supposed to shift flush or not.
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Did you remove the detent balls under those screw caps, they are located
in the main body of the t-case housing. If they arent removed, the shafts
are hard to move, and if it's not in 4WD the low shaft is locked into high
by the ball between the 2 shafts
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yeah i took them out i have one of the shift fork rods out already. i just dont understand why there is even a shift fork and sleeve on the top all i see that it does is engage the input to the shaft. maybe to put in true neutral.
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That shift fork engages the low range, it will also shift into neutral and
high range.
In high range it locks the input to the shaft that runs all the way through
the T-case and to the output where the driveshaft slides in, in low range
it disconnects the long shaft from the input and powers the gear cluster
that is in the front of the T-case, goes through those reduction gears and
then transfers the power to the long output shaft, giving you low range.
You will notice the low range gears all turn, and is probably what you didn't
get with the front/top shift shaft and fork, but the low range gears are always
rotating in the T-case, every day just cruising down the road in high 2wd they
are turning, that's why I went to a lighter weight T-case voodoo juice to reduce
drag and improve fuel mileage
Wild
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then why doesnt my front drive shaft turn if the low gears are all turning all the time.they are just free spinning on bearings which i think would not do much against the power. there is two different shift forks what does the top one do. my understanding is the top shift fork is always engaged to the front input and the second fork puts it in 4high 2high then 4low.
is that correct? BAck to my original question what would cause a grinding noise when putting the transmission in any gear and trying move forward. it is like it slips out of gear or just never goes in all the way into the gear. could it be a bad clutch if it happened while i was driving. feels like it just fell out of gear. it has made the grinding in every gear at sometime. so it is not gear specific. it has to be before or after where the power transfer is slipping and grinding.
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The shift fork in the back/rear is the 2wd/4wd shifter, the front is high/low
shifter, and yes the cluster of gears are on bearings, at least on the short
shaft, the other gear on the long shaft gets locked onto that shaft when
you shift into low.
I bet you have a bad engagement dog, and just a little rounding will cause
the grinding you hear, this is from being run low on oil, at least that's what
happened to mine
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ok so i got the top shift fork to shift up and down, but i dont understand how it can turn the shaft when it isnt in the right position. it doesnt contact the input teeth. so does it work?
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There are two options here, I could show you how it works,
and I can try to explain it to you, but you need to understand
how the T-case works or it will be a mystery to you, so I would
suggest you purchase a new (used) T-case to solve your problem.
Short of that I really need to get a closeup look at the parts to
determine if there is some damage to your parts, and if there
is, you still need the replacement parts, and a used T-case is going
to cost about the same as the parts you need to buy
Wild
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what type of gear oil goes into the tranny and the transfer case?
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I made up a batch of slippery voodoo juice for the T-case, should work
equally well in a trans, 1 part Mobil1Synthetic ATF and 1 part Lucas synthetic
gear oil aditive, this makes a nice light slippery lube that is yellow metal friendly
Wild
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I just use standard 80-90w. I tried running synthetic in my Tracker's transmission but it's a little to worn out and the lighter oil made the lack of good syncro's that much more noticeable. I couldn't shift properly until the transmission warmed up. So I went back to the straight 80-90 and have been happy ever since.