hey everyone rebuilt my transfer case 4 times in the past and thought i did a perfect job doing it but when alot of torqe is on the front eg deep mud i loose the front and have to mash the t case shifter all over until it engages again. i am wondering what would cause this it is a pain and could be dangerous, usually a high torqe situation is on a steep incline and if i were to loose the front i would loose traction, did i get the ball bearing thingies mixed up(size) or is something worn out? btw i have trail toughs 6.1 to 1 gears thanks 6feet

if you're running stock mounts one of your arms might be bent.mine was doing that and it turned out to be the long arm twisting.
  oscar

Could be the shifter sheet also!

Cwkick

Check your t-case mounts like AZ said...


-Eric

If it is not the above, it is prob. a bent shift fork, there are a lot of guys that go to the hardware store and buy a washer and put in there to shim it out so that it engages deeper on the splines but that is mickey mouse but cheap!

definatly not the t case i have welded it very custom and its tight as hell, when i hit deep mud for example theres a dom sound as the front disengages, then the shifter doesnt shift correctly until i wiggle it quite hard, move it back to 2 hi then back to 4 low, basically its as if the ring holding the front output side of the t case gear has slid back on its own under torque and the only thing i am not sure of even though i think i got them in right are the balls that go in there, theres 2 total and one is bigger than the other, could i have got them reversed? it really sucks and im going to a couple events where ill need it to NOT do that in a couple weeks. thanks everyone for the redponces, 6feet

bump.

bump.

I think you've tapped us out! My only suggestions are either bent t-case mounts / t-case not in line, loose/ripped t-case bushing mount, or shifter sheet (donut) worn. However, it has been my experience that the shift sheet won't cause it to pop out but will let the t-case get 'confused' and end up in nuetral. Then the operator must pull the stick and shift the case with a screwdriver or something to get the forks positioned correctly.

You mentioned it was popping out of 4 lo when you're underway. I've had that happen with bent mounts steel and another time with torn rubber bushing/mounts.

Good Luck, -Eric

yeah its like the fork for the front output is all that lets go, i allways have rear but the front just pops and doesnt work till i wiggle the shifter and bang the  fork back to where it needs to go, could the bottom of my shifter be worn to the point where it lets the fork slide to its disengaged position?

Do you have a body lift?