ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum

ZUKIWORLD Model Specific Suzuki Forum => Suzuki Samurai (All SJ Platform) 1981-1998 => Topic started by: JLynn1986 on July 30, 2011, 09:28:25 AM

Title: Transfer case stuck between 2 high and 4 high
Post by: JLynn1986 on July 30, 2011, 09:28:25 AM

I have an 87 samurai with a 5 inch calmini lift kit and 31/10.50 tires. When i went out to play it went in to 4wd easy but when i was done and trying to put it back in 2wd the transfer case shifter is stuck between 2 high and 4 high. This is the second transfer case that has done this to me. Any one have any ideas what the problem could be or a fix to it.

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: Capt on July 31, 2011, 02:53:54 PM

Check with LowRangeOffRoad;

The factory front output shaft has a very thin syncro gear.
As the also very small pilot bearing wears out for the front output shaft,
the syncro collar does not hold and lets it "Jamb" between 2wd & 4wd.

They have both, the bearing and a "Bigger/Better" output shaft to cure this.

CAPT

P S...This would be the time to pick out the lower off road gear set you ALWAYS WANTED!!
        And a complete transfer case bearing rebuild kit as you are going to split the case anyway !!

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: wildgoody on July 31, 2011, 08:09:56 PM

There is a part that the shift lever sit on, called the shifter sheet, yours
is worn out, and needs to be replaced, there are brass ones available
that should last the life of the T-case, and there are plastic ones also

Wild

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: Drone637 on July 31, 2011, 08:55:02 PM

What Wild said.  If you take the shifter out you can use a large screw driver to get things back into the proper place.

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: Capt on August 02, 2011, 06:39:31 PM

In My case the shifter sheet replacement didn't work.....
I just figuired that it had a lot of abusive miles on it.....
I installed a simple hook mounted to the floor, and a ring on the transfer case shift lever to keep it in gear
until I rebuilt the transfer case with 4.9 gears.

CAPT

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: JLynn1986 on August 03, 2011, 01:11:03 AM

It was the shifter sheet. Thanks for the help guys

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: Skyhiranger on August 04, 2011, 09:10:04 AM

Quote from: JLynn1986 on August 03, 2011, 01:11:03 AM

It was the shifter sheet. Thanks for the help guys

Cool.  Now you can come out and go wheeling with us on the 20th.

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: JLynn1986 on August 04, 2011, 11:50:02 AM

where are you going wheeling at?

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: Skyhiranger on August 04, 2011, 02:17:53 PM

Quote from: JLynn1986 on August 04, 2011, 11:50:02 AM

where are you going wheeling at?

Kansas Rocks.  Check out the meetings, activites and events section at zuksofkc.us.  It lists all our upcoming wheeling trips.

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: rockin35s on September 09, 2011, 11:46:44 PM

I've had this same thing happen to mine several times, and it was the bushing that these other guys are talking about. Right now my transfer case won't even stay in 2wd it will only go in 4low but that is because something in the transfer case isn't right, not sure what is wrong with it now. It has a bad grinding sound in it also, sounds like it is about to fly apart at any minute.

Title: Re: Transfer case stuck between 2 high and 4 high
Post by: wildgoody on September 10, 2011, 08:26:15 AM

I had a problem with a Sidekick case that was run low on oil,
and it wouldn't stay in low because of damage to internals so
there may be a problem inside your case from low oil levels

Wild