Backing out of driveway in 4 Hi heard a pop noise transfer case jammed in nuetral, cannot move. Any suggestion welcomed.
Thank You

I'm assuming your drive way is concrete or asphalt - you may have broken something in the transfer case.

You can try removing the console & transfer case shifter and sliding the shift rods with a large screwdriver - when you look down the hole you should see two rods with notches in them - right side selects HI/N/LO (you want to push that as far forward as you can to get it into HI) - left side selects 2/4 (you want that in line with the right side) so you can easily put the lever back, and at that point you should be in 4HI.

I was on ice when i had my problem. I have not been able to get a repair manual. I have the console plastic all off right now. The lever has 2  12 mm bolts one on the opposite of the other,my question is do i take them out to remove the shift lever.

I thank you for your reply

No - don't remove the bolts - there should be a metal clip holding the rubber shift lever boot to the housing, release the clip and pull the boot away from the housing, there should be a circular cap beneath it - get two large flat screwdrivers and depress the cap (it has a spring beneath it) and then turn counter clockwise - you should then be able to lift the lever free.

Try not to tear the boot - it's sold with the shift lever - $250 or therabouts.

Your info was absolutely correct. I inserted the lever back in after i moved the inner shaft with the screw driver, i now can do 4 lo 4hi and back to 2 whl drive. I am wondering if there is a part that wears in the shift lever? The vehicle has 65000 miles , i only use the 4 wheel drive during bad weather and in the summer to keep things working, of course there was an owner before me.
Any thoughts you have i will appreciate.

Thank You again

There is probably a piece of plastic below the shift lever that it sits on - at least most shifts have them, I really haven't looked at mine, because I haven't had trouble with it - usually if it's broken the lever will be fairly "loose" - you can shake it around.  If your shift is not loose, just consider it one of those things and forget about it, until it happens again.

Now that the transfer case shifts through Hi Lo, but the 4 wheel is not engaging. The air pump at the front is not going on. My question is there a way of checking this part to see if is bad or a fuse or circuit breaker in the system is out of order.

Any thoughts are welcomed Thank you

Yes - there is - so let's get started.

First - you can "troubleshoot" this with the engine off - switch the ignition on and shift the transfer case lever into 4WD and back to 2WD as required.

I would start be listening to the air pump - if the surroundings are quiet, you should hear it turn on, when you select 4WD with the ignition on.  Please note - if the pump is working, but because of a pressure leak (or other problem), cannot develop the required pressure, the 4WD controller will shut the pump off after 10 seconds.

If you cannot hear the pump running, disconnect it and connect a small 12V lamp or a test meter between the black & red wires in the harness and repeat the test - if there is no +12V (or the lamp does not light) check the following ...

a) the 4WD switch on the transfer case - this should close (short to ground) when the transfer case is in 4HI or 4LO
b) broken wires between the 4WD switch and the 4WD controller (under the driver's side dash), and between the controller and the pump module.

Let me know how it goes and we can take this further.

Thank you for your help. I put the suzuki on the lift and found a lot of ice on the cross member where the metal line changes to rubber before it enters the differential. I cleaned the ice and disconnected both ends, it looked like it had a small amount of oil. I blew compressed air through, hooked it back up and it is working fine. I had tremendous snow here this winter. I clean my driveway go out and the snow plow goes by and leaves a large amount of snow to push through when i return. I am thinking that that is what started my problem. Just as a precaution i am going to find some sort of insulation to wrap around this line.