Disconnecting transfer lever / linkage

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Joined
Nov 20, 2016
Threads
3
Messages
20
Location
Western Australia
My transfer lever is so bloody stiff i can only move between 4H and 2H using all my strength. I've sprayed everything with WD40 and it's not improving.

I read here [ Stiff Transfer Case Lever ] that you can remove the hub and disconnect the linkages back to the transfer case. Any idea if this should be my next move? I'm a novice at this stuff so any help much appreciated.

IMG_20161130_172251.jpg
 
You are in neutral when trying to shift right? Just checking, first things first.
 
Yes, in neutral and no wind up.
 
We used 4WD for the first time in a while (not sure exactly, but a few months ago) and was fine. Problem came when the missus got lightly bogged in sand and wanted to get into 4L. Lever was really difficult to move and i had to help from the passenger seat. Went into 4L when vehicle was stationary and in Neutral. Later that day found it really stiff to get back to 4H and 2H.

Since getting back home i've sprayed the lever and linkage with loads of WD40 and tried to free it up. Only with a lot of force can i move between 4H and 2H. Can't get into 4L.

I was figuring that if i can disconnect the linkage from the transfer case then i will at least know if the lever hub has seized up. However, i'm not entirely sure so open to any advice. Money is pretty tight at the moment so I'm hoping it's nothing too serious. Thanks a lot in advance. Cheers

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2000 105 diesel 1HZ
 
When was last time you changed the transfer case fluid and with what?
Not sure exactly when, although vehicle was serviced regularly at mechanics. Only the last service i did myself - just this week - where I checked the transfer fluid and it looked pretty clean.
 
In your picture, I can not see rust, sand or muck in area, but lighting is not very good. Your 105 may have different shift linkage, but regardless make sure it's not rusted, damaged or pack with sand/muck. Visually inspect the best you can. If mechanically comfortable in doing, keep pulling apart linkage as much as you can to clean, inspected from point your at. Which it looks like your doing.

Transfer cases are difficult to shift, even more so when not frequently used. This can be compounded when vehicle is parked for long periods. The gear lube sets in lower halve of T-case, and moisture will build over time corroding the rod the shift leaver slid on, at the top internals of the case.

Before moving to next step, which is disassemble of top end of case. I'd change the gear lube. To get a dab of lube from T- case on finger is not revealing. Drain into glass jar and inspect color. Run though rag or fine screen and inspect. I use 75W-90 Mobil one gear lube in the series 100. It's a good synthetic lube. Check your 105 manual for proper lube & weight. Remember to always change washers (gaskets) of drain & fill plugs when removed, or they leak.

The transfer case & front differential I find need change the most, based on color. Usually around 15K to 20K miles. I don't like additives, but when I do need to use a name I trust. BGK makes some good additives to enhance lubrication, it what most Toyota & Lexus dealers here use.

I always baseline every new to me vehicle. That is, I change all fluids, using top of the line products, that I know and trust. I also bring all factory recommended service up to date. I never mix different brand fluids, so changing is only way to know what to top off with.

Lets hope yours just needs good fluid change and exercising.
 
Thanks 2001LC! Yes, the linkage does look in good condition. There is not much in the way of mud or rust. I like your idea of changing the fluid; I'll see if i can pick some up soon. I must admit i am very worried that this will turn into a worst-case scenario. With a bit of luck some new fluid and bit of movement can free it up. Will report back.
 
OK... here's what i found. Replace fluid and nothing has changed. So i'm focussing on the linkage. The linkage is protected by rubber 'thingys' (grommets?), so my liberal spray with WD40 is unlikely to have done much. I told you I am very novice at this, so please excuse the basic questions here:

How the hell do i get those rubber thingys off? I can seem to peel them back.

This working space is ridiculously tight. I could squeeze my little camera in, but find getting my hands in more difficult. Am i in danger of dismantling the linkage and then not having enough working room to put it back together again?

Any advice in general on how to dismantle the linkage much appreciated.

Cheers

tightfit.jpg
 
OK... tried to pull one of the rubber things with some long nose pliers and tore it in half :(

So... looking down from inside the cabin here is the view. To dismantle the linkage, should i be removing the bolt A or bolt B? I guess i'm trying to find out if the transfer lever is stuck, or if the linkage is stuck, or if it's something much more expensive.
topview.jpg
 
Before you attempt to disassemble. Try spraying with penetrating oil like PB blaster, hit all linkage spot & nuts. Also drive for a while to let new gear lube get worked up to the internal parts of the transfer case. I assume it still drivable. Do both (drive & spray) over the next few weeks, spraying more PB blaster every few days.

"A" is nut holding linkage arm on to bracket. "B" is to adjust length. I'm not familiar with this linkage, but you should find that the inner side of "A" has two opposing flat sides. That is, just to the inside side of the bracket. This is where you put a wrench to hold the bolt as you turn nut "A".
topview.jpg
 
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Yes, will be drivable once i put the seat back in. Will give it a go in a few days. Thanks! Will report back :)
 
WD40 is primarily a water dispersant, and in my experience, not particularly effective in loosening corroded parts. If you're game, Auto trans fluid and acetone 50/50 apparently works quite well, but I've had good results with CRC myself.
 
I agree with @AussieHJCruza WD40 is not a penetrating oil. I'd be cautious using acetone, as it will dry out rubber, which may lead to future cracking. CRC, PB Blaster & Sea Foam are all have penetrating oils.

First I'm just trying to give you some basic mechanical advise. Your series 105 transfer case linage looks different than what I'm seeing in the 2000 100 series Land Cruiser FSM (factory service manual), so I'll be of limited help. You need some of the 105 guys to step-up to the plate and help out here. Possible the 80 series is more like what you have, check with that sections of mud as well.

Hopefully you examined old gear lube for amount, color, water (cream white gunk), metal pieces or any contaminate as this can be revealing. What did you from drained gear lube?
Note: It's necessary to replace gear lube drain & fill plug washers (gaskets) when every removed, or they leak.

Looking at your pictures, I doubt the ball & socket of the linkage connecting arm pivot points (that was covered with the rubber boot) are frozen. It looks to me as if boots are doing their job. Easy to determine, just twist the linkage connecting arm back and froth slightly clockwise then counter clockwise. It will not twist much, but if it twist any, even tightly (new would be tight), it is not frozen. Actually it does not look like any of your linkage is frozen to me.

Ripping off that boot, you'll need to replace it once shifting problem solved. Check with a local Toyota parts department, you may need to buy linkage connecting arm to get that boot. You can cover with marine grease as a short term fix, but not yet.

Keep driving until transfer case gets too normal operating temp. Stop, put in neutral and try shifting transfer case to low. Make sure you follower your 105 owners manual shifting procedure precisely. Keep repeating once or twice a day, over next few weeks (exercising). And keep adding your penetrating oil of choices to linkage nuts, this is to make removal of nuts easier. The more you do both the better your chance of freeing this up without pulling T-case, and easier time you'll have removing linkage connecting arm nuts.

While doing above detriment if shift handle lever is frozen. This should be apparent now just by moving shift handle back and forth. If it rocks a little, moving linkage a little as it does, then shift lever is probably ok. After the two week procedure, if no change in condition, then remove the nut "A" to free up shifter handle lever from linkage. Now try moving shifting handle lever. If it moved freely full distance, that's not your issue.

Next would be to see if you can move shift arm "C". But this will impossible to do, and since other above points you've checked are working properly, I'll bet this will not move. Even in a loose transfer case, this takes a lot of muscle to move even when using leverage of shifting handle lever & linkage. It's not likely (looking at your picture) it's frozen externally. So bottom line if exercising T-case doesn't fix issue, you'd need disassemble top end of transfer case next. I don't not recommend you do this on your own. First you need correct FSM & tools along with good mechanical skills. You'll need hands on help for this.

I'm still very hopefully your transfer case has just frozen up. If you're not hearing any weird sounds from it the gears, there're probable ok. If you get any improvement over next few weeks it will be a very positive sign. There may even be other chemical's you could add into transfer case, too help loosen up first and better lubricate second.

Good luck.


Shift arm C.jpg
 
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Hi 2001LC. Really appreciate the help you are giving. Really useful to someone with such limited experience such as myself. I'm away from home for a while - when i get back in a few days i'll reply to your email fully. Many thanks indeed! back soon, Pete
 
I'm back.

I did look at the gear lube and it looked pretty old, but no water and virtually no debris on the magnet.

oil.jpg


I agree with you that the ball and socket is not frozen. It twists a little bit so all good.

Yes, will have to replace the boot. Kicking myself for that.

Now i am back i will do some driving around in the 105 and start shifting the transfer lever around. With a lot of effort i can get it to move. I'll add some CRC to the linkage nuts every now and again.

My money is that the shift lever is jammed up. I think i'll have a go at removing nut 'A' and seeing if the lever moves easily.

If i can't get it working at this stage then i think it'll be off to see Mr Mechanic.

Many thanks for your help to date 2001LC. I'll update this thread as i find out more.
 
I'm back.

I did look at the gear lube and it looked pretty old, but no water and virtually no debris on the magnet.

View attachment 1364187

I agree with you that the ball and socket is not frozen. It twists a little bit so all good.

Yes, will have to replace the boot. Kicking myself for that.

Now i am back i will do some driving around in the 105 and start shifting the transfer lever around. With a lot of effort i can get it to move. I'll add some CRC to the linkage nuts every now and again.

My money is that the shift lever is jammed up. I think i'll have a go at removing nut 'A' and seeing if the lever moves easily.

If i can't get it working at this stage then i think it'll be off to see Mr Mechanic.

Many thanks for your help to date 2001LC. I'll update this thread as i find out more.
You're welcome!

Just to see what all may have been going on, can you measure the amount?
If you tossed old lube, just fill same pan to approximant same level to measure.

Also some history on 105. Like was it setting for long periods of time?

Lube, oils & gasoline setting in tanks & cases, gives off moisture that rust parts not submerged. They do like to be driven, and all switch nobs and gears used.

Here's my last rear differential at 40K miles. Transfer case lube looked about the same at 15K. This after repeated flush using M1 synthetic. Looking through glass into sun does make it look better, than sitting on beach.
Differential Rear 9-10-16 (42K use).JPG
 
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Luckily i haven't yet disposed of the lube. This container is 2 litres, so looks to be almost 1.5 litres (50 US fluid oz). I had checked the level before draining and it was almost up to the filling point, so i think that's the appropriate amount. I filled up with Penrite PRO GEAR 75W-90 (Full Syn.)

oil.jpg


history: The 105 is driven once or twice weekly. We hadn't been in 4WD for a while (four months maybe). That was a week of mud...

mud.jpg


Update: I've sprayed the transfer lever with tons of Inox (like WD40) and of course changed the transfer fluid. I took the 105 for a drive yesterday and - with a bit of a struggle - made it into both 4WD and 2L. I shifted back into 2H and - as i was reaching around 90 kph (55mph) i thought the gears were sounding a little funny. I pulled over and pushed the transfer lever hard into 2H again. That seemed to do the trick and it sounded fine. However - when i stopped and changed back to 4H there is grating noise as the speed picks up (at third gear). I wonder if it's because the transfer lever hadn't pushed far enough into 4H? I tried a couple of times before going back to 2H.

So... the good news is that the transfer lever is beginning to work. The bad news is that there is now this new horrible sound in 4WD.

Next steps for me: Check the transfer fluid i put in and make sure it's settled at the correct level. Continue to spray the hell out of the transfer lever. Any suggestions for anything else i should do?

Best regards! Peter
 
Lubing your propeller shaft yokes & spider joints after those muddy treks, along with power pressure washing entire undercarriage is a very good idea.

Keep working (exercising) those gears, either it's going to get better or it will fail. Just keep close to home until for now.

Good luck!
 

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