Hey everyone. A while back I had started a thread about my tfr case shifter making a wild vibration and rattle noise while accelerating in 2nd gear. There weren't any answers uncovered, so I just wrote it off as an annoyance. Unfortunately, that rattle has turned into more.

When in 4-high, the transfer case shifter bounces out of 4-high and into 2-high and gets completely locked into place. It still drives fine and it's definitely in 2-high, but it simply cannot be moved no matter what. Not with the clutch in, not with the sam stopped, or jacked up in the air. The only way to get it working again is to pull the transfer case shift knob out and re-insert it. Then it goes back to shifting just fine. This doesn't happen in 4-low, just 4-high.

When I take it apart, everything looks good. Plenty of gear oil, bushing is perfect, movement is snappy exactly as it all should be. Not sure where to go with it. Any ideas?




-motofabio

Bump! Any ideas?


-motofabio

LROR http://www.lowrangeoffroad.com/suzuki-off-road-parts/sidekick-tracker-x90/clutch-ransmission.html has two kits that should fix your problems.  It sounds like your Transmission Shifter Ball Bushing is bad, and when replacing it you might as well replace the Transmission Shifter Seat Bushing as well for about $12.
When you replace those two, you can enjoy wheeling your rig again.

Am I understanding this correctly that a worn bushing in the transmission is causing the transfer case shift knob to vibrate, pop out of place, and get locked up?


-motofabio

The bushing sits under the shifter sheet down in the tower.   The shifter itself nestles down into (and through) the shifter sheet (the concave bushing in your picture) and into/inside the shift tower.  Over time, both the shifter sheet and this shifter bushing wears against the contact with metal and allows excessive movement of the shifter/shaft.

The pic below shows a new shifter sheet on the left and the old worn sheet on the right.  Look at the difference on the thickness of the inside lip of the concave surface.  Same type wear occurs on the bushing, new bushing on the left and old one on the right.

My shifter was getting really sloppy after almost 200K miles.  Replacing these bushings tightented it up considerably.  Rebuilding the transmission tightened everything up.

I can't say that your transmission is causing your transfer case problem, but your bushings inside your transfer case shifter may be worn excessively too.

I guess I'm just not putting two and two together on how a worn bushing on the transmission shifter could have any affect on the transfer case shifter.