Got Shafted

[HoundDog]

It’s midnight. I have get up in five hours for work. Up late installing a twin stick kit. The shaft on my split case that controls high/low fell into the case. WTF? Is the only solution to pull the entire transfer case now? No way I’m getting it back out from the top with only two inches of clearance. Like my grandma used to say….so mad I could spit!

1980 FJ40, H42 + split case

 

[3_puppies]

you're not the first one that this has happened to.
I'd remove the pto cover plate and see if there is a way to work something in there and pry the lever back up before splitting the case

 

[Rocky_LC]

I got a speedo gear & shaft out through a hole like that with a magnet on a stick…. but I was really lucky…

 

[peesalot]

X2, remove inspection/pto cover and push up, put a rubberband around the top to keep up next time.

 

[HoundDog]

Got that sucker back out using two magnets, then clamped it with a skinny pair of vice grips, and used one of my daughters hair bands to hold it in place.

Anyone know if it’ll stay up if I twist it or will it always want to fall back in?

 

[3_puppies]

AFAIK the only thing that keeps the rod in place is the shift lever that attaches to the top

 

[Living in the Past]

This diagram shows how it fits in the notch in bottom of the shaft that moves the fork.

Have to be sure when you attach the arm the lever is seated tight inside the notch.

 

[HoundDog]

Thanks for that. Last night I was able to pull the shaft up more to where it seated inside the notch. The key was to wrap a rubber band around it, slide it down, and that held it in place while I slid the new lever arm on from the top.

I connected the linkage and took it for a test drive. Everything worked perfectly. The independent levers provide very good feel of positive engagement. Very pleased that I averted a full T-case tear-down.

Thanks for the help.