82 pickup stuck in 4x4 after 4.7 gear intall

[hairy_apple]

Replaced the gears in the wifes truck last week, finished buttoning it all up today and went to test it. Worked fine, no wierd noises, nothing strange.... untill we went to go back into 2wd to go for a road test. It went into 4 high, but then wouldn't budge. Just stuck. Can't go back into 2lo, can't go back into 2x4. I rolled the truck back and forth, unlocked the hubs, relocked the hubs... nothing is working.

We were all excited to go out and wheel it tomorrow... now it's looking like we're going to be taking the case back out to figure out what's wrong with it.

I have no idea where to proceed to figure out why it's stuck. Any ideas?

 

[ferg]

Pull the shifter and check the shift fork positions. Check for proper range and function, including the lockout poppet.

 

[KLF]

Yes, pull the shifter and look at the forks. You might need to take a prybar and pop them so they are in alignment. Or it could be that the shifer was installed wrong.

One time several years ago my son was out wheeling and something "popped" in the transfer, and it was stuck in 4WD. He had it towed to my house, and all I had to do was remove the shifter, move the forks, and put it back on. Somehow he got the truck twisted up and the shifter popped out of the fork. It was an R151F that he had swapped into his 4Runner, and he discovered that he didn't cut the hole in the floor big enough.

 

[hairy_apple]

I just took the shifter off and couldn't pry it. I know WHAT its doing, just not really sure why. We must have shifted it 100 times on the table to make sure it was shifting OK, and everything seemed OK. Took it for a drive in the field and it got stuck. No idea WHY it's stuck.

I am pretty sure I can unstick it now that I've got the shifter off, I think a good pry will do it, but I don't know what caused it and if it does it again somewhere, we're going to be stuck in 4x4 and need to get towed home too.

What is causing the shift forks to become misalined? Is there a wrong way to install the shifter? It seemed like it was the same either way... hum... maybe that's it.

It's super frustrating as my cruiser is down for a while and THIS is going to be our wheeling camping truck this summer, the longer it's down the less we get to go camping and that's making me sad real fast.

 

[Sam Stewart]

I had a similar problem when I did my duals. Turned out that one of the collars was binding. When we had it on the bench it was fine. When we tightened it down to the trans it bound up.

Sent from another Galaxy

 

[ferg]

Time for a twin stick?

 

[hairy_apple]

Yeah, I'll have to call marlin crawler tomorrow and see what they say. I have no interest in taking the case back out until I know what's causing it to jam up. Didn't make it over to my parents house today to work on it, don't have a garage here and I don't like laying in the dirt to work on stuff. Going to call tomorrow and see what Marlin's guys say.. and go from there.

I can't really afford to put another dime into her truck right now, we've got a ton of stuff around the house that needs the monies more then we need a twin stick or I already would have. :/

 

[pappy]

You boys are probably over analyzing this. Look at the attached pic. I want you to make the forks inside your shifter look like this. A big screwdriver works great. Both forks need to be in the forward position. You will insert your shifter into the [==] at the top. That will put the shifter in 4H, and allow the shifter to move left and right so it can be shifted either back into 2H, or into N.

 

[ferg]

OP - results?