transfer woes.

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

Joined
Aug 2, 2008
Threads
15
Messages
216
Location
Perth, Western Australia
Looks like my transfer case has finally given it all up....

On my way home from work this afternoon, I thought I'd check out this dirt track that I'd been eyeing off for the past week or so. found it to be a lot of fun - an open sandy area surrounded by climbs of varying grade. Needless to say I gave them all a go, didn't go too hard though. Mostly in low range, 2nd or 3rd gear.
After having a bit of fun on the sandy hills, I set back for the road, just a short way off. So I tried to shift from low 4 to high 4, but the lever felt like it had no real resistance and kinda slopped over to the H4 side without any definite clicking. I thought it was odd, but knew there was something wrong for sure when I accelerated away and felt the truck was still in low 4.
I spent a good 30 minutes on the side of the road trying to get the transfer back into high range, I went underneath the car and checked the linkages and they all appear to be fine. I can easily push the high / low range selector on the T-case itself with my fingers, there is very little resistance. It shifts from 2 to 4 wheel drive fine. Occasionally it would shift into neutral.
In the end I had to crawl along the edge of the highway at about 30kph all the way home.

I have an H55f with T-case sitting out the back waiting to be put in. But I'm not sure I'm quite ready to do that yet though. So I was wondering if anyone here has had this problem or have heard of it before. It seems to me like the internal shifting lever has broken or disconnected. Is there anything anyone can think of to remedy my situation short of pulling the T-case and transmission off? The car is my daily driver so it means I'm going to be a little stuck!
 
Anyone?....

I suspect this pin has sheared:

transfer exploded view.webp
transfer exploded view.webp
 
Either the pin has sheared or the "L" shaped lever to the left of it has broken/sheared, I've seen it happen on occasion. Have you verified the shift linkage is all in tact underneath. There is a bolt on lever that bolts to the shaft that protrudes into the transfer case, it could be slipping there?
 
I had this same thing happen once and it was the "L" shaped lever as Kurt mentioned.

If you drain the fluid and open the inspection cover on the transfer case, you can see for sure if that lever is seating properly or not. When it happened to me I took a long screwdriver and reached in through the inspection hole and pushed the "L" piece back into place while a friend shifted the transfer case back into "high" so that I could get home. If this is your problem, don't try to shift the transfer case back to low until you fix it as you will have to repeat this method all over again.

Good luck

Cheers
 
There is a bolt on lever that bolts to the shaft that protrudes into the transfer case, it could be slipping there?

I hadn't thought of that (hopefully it is that!) ... I'll check this afternoon. Thanks!

I had this same thing happen once and it was the "L" shaped lever as Kurt mentioned.

If you drain the fluid and open the inspection cover on the transfer case, you can see for sure if that lever is seating properly or not. When it happened to me I took a long screwdriver and reached in through the inspection hole and pushed the "L" piece back into place while a friend shifted the transfer case back into "high" so that I could get home. If this is your problem, don't try to shift the transfer case back to low until you fix it as you will have to repeat this method all over again.

Good luck

Cheers

excellent! I was under the impression that I'd have to remove the transfer case in order to get it to some how shift back into high range.

In the mean time, I've managed to get my old falcon running, so I have mobility and I'm contemplating just getting on with the H55 install. There's no harm in checking the linkages as described above though.

Thanks heaps for the help dudes, very useful information!

Cheers,

Matt
 
bit of a background to this one...

Ok,

So I investigated...

and it seems that it was that "L" shaped lever, as suggested by Kurt and MadmanCruiser, that had lost its connection to the internal shifting rod. But there's more to this story...

It seems that this has happened before.
When i felt around to see if the bolt was loose, etc. I found that the linkage connector on the top of the "L" lever wasn't secured all the way down to the base of the shaft - there was some space between it and the top of the transfer case. So I thought straight away "ok, excellent! the bolts came loose and the linkage has migrated up the shaft, thereby losing any useful connection, therefore not shifting"
But upon further investigation, i felt something unusual around the shaft (it was getting dark and impossible to see) but it felt like a hose clamp. So I removed it and it was, indeed, a hose clamp! Then I removed the linkage from the shaft. I fiddled with the shaft of the "L" lever, trying to see if i could regain connection by feel. But it was very loose and started to drop into the transfer case. Eventually it dropped so far in that there was no longer any shaft left protruding, and I could not grab it any more.

It seems like a previous owner encountered this problem before, manoeuvred the "L" lever into place, and secured it there by means of the hose clamp, and simply bolted the linkage onto the remaining space left on the shaft (which wasn't much). So it was just a matter of time before it came loose again.

Seems to have worked like that for quite some time, the PO was honest and looked after the troopy, was a diesel mechanic, and so I don't think he would do such dodgy workmanship. So must have been the owner before him, or before him...

Anyway, I'm going to use a strong magnet to pull the lever back out again, and then use that magnet to hold the shaft up and into place while a properly secure the linkage. Should work for now.

But, its a reminder, pretty much saying "PUT THE H55F IN!"

That was a bit long, sorry.

But thanks heaps for the help!

:cheers:

Matt
 
Good luck, do the H55...you won't regret it :)

Cheers,

Adam
 

Users who are viewing this thread

Back
Top Bottom