Transfer case will not engage front axle-still

spdwaver1 · 08-19-06, 03:02 PM

Should have a disorganized mess in the garage by 9:30 p.m. tonight, from which I will search through the debris to find my problem.

I will also get to see if this new case is producing any more metal shavings after the last drain and refill I did. (see http://forum.ih8mud.com/showthread.php?t=103882).

Thanks again for all the help on this matter.

spdwaver1 · 08-19-06, 09:01 PM

Getting started right now....

spdwaver1 · 08-19-06, 10:05 PM

Well, I cannot take the four-bolt housing off far enough to see the inside of the nose cone to view the coupler (the frame is in the way), but what I can see is a very badly worn, and even shredded looking shift fork. Guess that is what I need, for one thing. This also may have been the producer of the metal chunks I found in the case when I drained it a couple weeks ago.

So, it would appear that the shaft is so worn that it is not even grabbing anything. Am I correct in my conclusion?

spdwaver1 · 08-19-06, 11:17 PM

The fork is twisted, as you can see. It is worn a few different ways: shaved, bent, twisted, cut, etc. Also found the silver source that I found on my filler plug...very fine and hard-packed to the consistency of modelling clay, with some larger shavings (for added texture).

Can anyone tell me by the series of pics if the rest of the parts in the nose cone appear to be in good condition?

Nothing seems scored as a result of the fork, and the coupler still slides freely and engages the front output shaft (now it engages!!!!!!!!).

spdwaver1 · 08-19-06, 11:27 PM

Poser, I see that the coupler is facing the correct direction as you described - the thicker side facing the transfer case, rather than outward. What would have caused this thing to wear like this? My dad, the PO, installed it himself, and it was not this badly worn. It only has about one thousand miles since it was installed. Only one thing I can think of: The vacuum lines were probably reversed, causing it to be engaged this whole time?? Here are the images:

The silver clay...

Bent fork...

Another shot of the front shift clutch sleeve and teeth. If these appear normal, then I think I only need to replace the fork.

Waddya think?

spdwaver1 · 08-19-06, 11:42 PM

My thoughts:

I see by virtue of the polished look of the thinner end of the sleeve that the fork was resting against it, and not in the groove.

Judging by the lack of wear or polished appearance on the sleeve groove, it would appear that the fork was nowhere near the groove.

Having said that, would I be correct in positioning the fork in the groove of the front drive clutch sleeve when I get the replacement fork?

spdwaver1 · 08-20-06, 01:34 AM

Nevermind, I answered my own question.

spdwaver1 · 08-20-06, 01:53 AM

What would have caused this thing to wear like this? My dad, the PO, installed it himself, and it was not this badly worn. It only has about one thousand miles since it was installed. Only one thing I can think of: The vacuum lines were probably reversed, causing it to be engaged this whole time??

Answers to my own questions:

A. The shift fork was installed while the shaft was in the engaged position toward the rear, and not in the groove of the sleeve itself. Completely missed the mark.

B. While the vacuum had been working properly, it was forcing the fork onto the outer part of the sleeve, causing wear to the fork, in the perfect shape of the sleeve.

Sound about right?

Poser · 08-20-06, 08:10 AM

Clean it up, put a good used fork in there, put it together correctly, and run it.

Good luck!

-Steve

spdwaver1 · 08-20-06, 11:41 AM

My thanks to you again Steve, for leading me directly to the issue.

spdwaver1 · 08-21-06, 03:32 PM

Got the new fork in today. Used from SOR, 35 beans. In pretty good shape for a used one.

spdwaver1 · 08-21-06, 03:44 PM

For the sake of others out there that will have a similar issue, here is what a brand spankin' used fork should look like. Also shown is the current state of the fork still residing in the unit.

If yours appears like the latter, please do yourself a favor and change it out. As soon as someone tells me how to remove the fork from the unit, I will explain how easy it was.

spdwaver1 · 08-21-06, 08:46 PM

Well, got it fixed. AND, it was an easy fix, as soon as I was clued into what was wrong. Turns out the bolt end should have a notch for a flathead screwdriver, to hold the screw while the nut is turned off. Mine was worn flat, and that is where I experienced the issue of not being able to complete the job.

It works.