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transfer case popping out of 4x4 hi...please help

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Offline W.O.T

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transfer case popping out of 4x4 hi...please help
« on: November 19, 2006, 04:13:35 PM »
i have a 90 samurai with a grsII transfer case from petroworks.  the transfer case is only about a year old but im having problems with it coming out of 4 Hi.  4 low is working fine but sometimes it just pops back into 2wd when i get any kind of load on it while in 4 Hi.  im new to the samurai world so im kinda lost.  i was told it was possibly a shifter plate???  also the tranfer case shifter seems to vibrate alot at times chattering back and forth even hitting the body.  the tranfer case does have heavy duty mounts not sure what the kit is called but im pretty sure its the best kit available.  please help this is really bugging me.  thanks       
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Offline zuksofhazzard

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Re: transfer case popping out of 4x4 hi...please help
« Reply #1 on: November 19, 2006, 04:25:38 PM »
Possibly loose bolts on the mounting arms.

Loose or bent mounting arms.

Shifter boot may be keeping it from going all the way into selected gear.

I'd check the T-case arms first.  ;)
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Offline W.O.T

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Re: transfer case popping out of 4x4 hi...please help
« Reply #2 on: November 19, 2006, 05:34:11 PM »
thanks for the reply.  actually the metal piece that goes around the boot was the original problem.  i removed it and it worked fine last weekend didnt pop out once.  then today it happened right away.  i will climb under it tomorrow and check everything out one more time.   
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Offline mrfuelish

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Re: transfer case popping out of 4x4 hi...please help
« Reply #3 on: November 19, 2006, 07:01:55 PM »
You prob. need lower diff gears and weld the long arm on the frame on the inside to keep it from flexing and tearing off.
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Offline W.O.T

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Re: transfer case popping out of 4x4 hi...please help
« Reply #4 on: November 19, 2006, 09:18:26 PM »
i think it has stock gears in the differentials but its just re geared through the transfer case.  i bought it from a friend who never had the problem.  he installed the heave duty mount kit and hasnt used 4X since it was installed.  then i buy it and its acting up on me.  i dont think its a transfer case problem more of a mounting problem the way T case shifter jerks all over the place under a load and just pops it out of 4X
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Offline kf4zgz

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Re: transfer case popping out of 4x4 hi...please help
« Reply #5 on: November 20, 2006, 04:17:29 AM »
If the tcase shifter is jumping around a lot it is probably hitting the edge of the hole in the  body and knocking itself out of 4wd.
Take the boot off and drive it and see how much it moves.
I'd bet there is a tcase mount problem. The stock rubber one get weak, crack, flex, and tear apart.
 replace them w/ new tcase polybushings.....the bolt thru type really stopp the shifter shake.

Matt
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Offline Drone637

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Re: transfer case popping out of 4x4 hi...please help
« Reply #6 on: November 20, 2006, 11:07:42 AM »
Rocky Road sells the Bullet Proof mounts for pretty cheap, I found it easier to order theirs then build my own.
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Offline sklope

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Re: transfer case popping out of 4x4 hi...please help
« Reply #7 on: November 20, 2006, 11:33:33 PM »
I had this problem with my tracker when I first bought it. After looking at, over, and under the shifter, I crawled underneath the tracker and found that the cross member that holds the transfer case in place was bent pretty good :o. After a little persuation with a big pry bar I was able to move it back in place ;D. I also put a body lift on my tracker and shimmed the transfer case up some so that the shifter would sit better inside the tracker.
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Offline W.O.T

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Re: transfer case popping out of 4x4 hi...please help
« Reply #8 on: November 21, 2006, 10:34:59 PM »
i cant figure this out.  ive checked all mounts.  the transfer case looks a little crooked slightly from under the samurai.  maybe i will try the stock mounts again.  it does have the heavy duty mount kit from rock road.  i took the boot off today and tested it so i could watch and see what was happening.  anytime i get in 4 hi it just pops out after a min or so of driving mostly on hills.  4 lo still working great.just strange because it feels like it clicks into gear perfect then it just bumps itself into 2wd some how.     
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Offline daddyizzle

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Re: transfer case popping out of 4x4 hi...please help
« Reply #9 on: November 22, 2006, 08:03:55 PM »
I had an 87 that did that. I would put it in 4 hi to drive on ice, snow etc. and as long as it was under load, it would hold. As soon as I let off the gas the slightest bit, it would pop out. At first, I didn't notice except that the sammy slipped alot. When I suspected it happening, I noticed the 4wd light go out. I would hold it in gear while I drove but that was a pain. I thought it was because the trasfer case had something worn in it. Now I'm not so sure.. The other thing I thought it might have been was the bushing or something on top not doing it's job. No way of knowing for sure now. I traded it off so I will see if the new one does it.

I think I would call petroworks and talk to the tech guy. Maybe they'll replace it or atleast tell you what could cause it. Unless you were doing some hardcore stuff, I wouldn't expect this to happen. This will make me think twice about buying one of their transfer cases if this is going to happen. How they handle this can decide whether or not any of us buy their product. I suspect they'll want to help make it right.

Let us know what they have to say or how they handle it.

-Adam

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Offline W.O.T

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Re: transfer case popping out of 4x4 hi...please help
« Reply #10 on: November 23, 2006, 12:56:34 AM »
yes i will get in touch with petroworks asap.  the previous owner of the samurai (a friend of mine) had the same problem when the transfer case was new, and called them up.  they were doubting him but they took a look at it and turns out they left a bushing out, that was causing the problem.  so it worked great for him from then on.  he installed the heavy duty mount kit from rocky road then i bought it shortly after and its giving me problems.  im getting the feeling im going to have to spend some cash to have it rebuilt.  but well see what petroworks says and ill get back to the boards.  thanks guys
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Offline W.O.T

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Re: transfer case popping out of 4x4 hi...please help
« Reply #11 on: December 04, 2006, 09:38:06 PM »
I called the petroworks tech line and was told it was probably a mounting problem.  The t-case mounting kit is the spidertrax kit from petroworks.  I pulled that off and put the stock mounts back on and the problem is still there.  Anytime i start to get any load on the thing it just clicks back into 2wd high.  I have to stop and shift it back into 4x.  4x low works great but i really need this thing fixed.  I dont have much knowledge about transfer cases, so if anyone has any ideas i would really appreciate it.  im really hoping that nothing is wrong with the transfer case but thats what it is looking like.  Any help???   
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Offline greenmachine

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Re: transfer case popping out of 4x4 hi...please help
« Reply #12 on: December 04, 2006, 09:52:01 PM »
Probably not your solution but I had the same problem. I tore everything apart three times and found nothing wrong . Later in rotating the wheels I noticed that I had two different tire sizes on the car. I later came to find out that some bonehead kid at the tire shop put two different size tires on the car. Maybe I was the bonehead for not noticing. Good luck
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DAC1138

Re: transfer case popping out of 4x4 hi...please help
« Reply #13 on: April 02, 2007, 01:58:35 PM »
Quote from: greenmachine on December 04, 2006, 09:52:01 PM
Probably not your solution but I had the same problem. I tore everything apart three times and found nothing wrong . Later in rotating the wheels I noticed that I had two different tire sizes on the car. I later came to find out that some bonehead kid at the tire shop put two different size tires on the car. Maybe I was the bonehead for not noticing. Good luck

I'm betting it's tire related, as you were hinting. I went off the road one icey night (didn't have 4 wheel drive on) and my front end got knocked out of alignment really bad. Like my steering wheel was turned about 60 degrees counter clockwise. I don't really know what fixed it, because all in one day I got new tires installed and a front end realignment, and afterwards the problem was fixed. My old tires were all the same size. I'm positive of that. But I think it was the alignment that fixed it. Not sure if this is the problem, but you could look into it.
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Offline daddyizzle

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Re: transfer case popping out of 4x4 hi...please help
« Reply #14 on: April 02, 2007, 02:24:17 PM »
My old sammy that did that had all identical tires all the way around. I don't think it was out of alignment because it drove down the road straight as an arrow for the two years I had it and I never noticed any unusual tire wear, in fact I never noticed any tire wear at all. The tires even had some light dry wrought.  But maybe if you do get it aligned and have identical tires around, it will solve it. I would be surprised. It just doesn't seem like mismatched tires and/or a bad alignment could do that.

Anyone? Anyone?

-Adam
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