H55F transfer box loosing gear?

[Blade]

Hi guys

My transfer box is behaving weird. When I switch back from H4 down to H2 (and make sure the lever is all the way pushed
to the front) it happened already a few times that when there was power on the drivetrain (going uphill but also
happened going downhill) it made a loud *bang* and it lost somehow power, like it would switch to neutral, 1 second later
another loud *bang* and a shock and the gear was back in.. this usually happens a few times.. I then switch back to H4, then
back to H2, sometimes it helps, sometimes I need to do this 2-3 times, then it's good and I can drive as hard as I want,
no problem!
Anyone knows what this could be?
It's a HZJ75 with a H55F transmission. I know that a gear in the transfer was exchanged for a stronger version or that
a weak spot was reinforced like that.
Thank you for any comment!

Michel

 

[Tapage]

Hard to tell from the outside .. the good news is you can pop the rear half of your BF1A t-case and do all the job ( rebuild ? ) with it mounted .. ( well the front half )

Pic when I did mine ..

 

[kbushnz]

Check the linkages are adjusted correctly. Underload they could be on the edge of popping out....
My transfercase pops out into N when under heavy load while winching and driving...(PTO)
Not 100% sure if its either the gearbox twisting on its rubber mounts with all the load and pulling on the linkages or its the sliding force on the gears forcing them apart...Bungy cord on the lever solves the problem.

 

[Blade]

Yeah, I already thought that it might be easier to rebuilt than the gearbox! At least my gearbox problem is solved, it was only the ball/spring that was too weak.

It happened yesterday again! This time the car was stopped and I could rev the engine and heard and also felt (my hand was on the transfer shift lever) that the gears were spinning and just touching each other! But they suddenly engaged again!

I checked afterwards at the campsite the lever positon... I shifted to H2 and removed the lever at the transfer. It felt like it was enganged in a correct position. I switched the small lever at the transfer case to N and 4WD and it felt tight. I felt the ball/spring engaging very well. Also back to 2WD I felt it very good how it engaged. I reconnected the shift lever coming from above and it pushes the lever nice against 2WD..

The big bracket at the H55F holding the lever from going to N has maybe 1-2mm of air between bracket and trans shift lever. That means, I can push the shift lever in H2 to the N direction for 1-2mm. But when checking under the car the ball/spring was still engaging well in 2WD. It just started to compress the ball/spring a little bit, but it was still far away from going to N!

So not sure HOW it can jump out to N when it does that!?! Is there anything IN the transfer case that can worn down so much, that it could make it jump to N and back alone?

It already happened when accelerating very moderate! And it always jumps back to gear doing a very loud *bang*, something that doesn't sound healthy! ;(

 

[Blade]

could be the reason that I press the clutch sometimes when shifting the transfer? My friend just told me that you should NOT press the clutch, otherwise the gears might not engage correctly?

 

[Blade]

today it happened on H4! But the lever popped over to the Neutral position! When in H2 it doesn't (can't) go to the N position. So not sure the lever is really not being pushed by force to the N position when in H2?

I also checked, when accelerating, the lever that is so close to the chassis goes AWAY from the chassis due to the transmission flexing by the engine torque. So I don't know how it could force the lever to the N position when accelerating. But I usually loose the gear when accelerating or engine breaking...