RTH! Truck Stuck in Low Range!

[Tigris]

Help!


So, I recently discovered a minor leak in my KZJ78 transfer case, and I was able to pinpoint it to the small oil seal at the top of the transfer case where the shifter linkage goes into the transfer case.

I managed to disconnect the bellcrank linkage from the selector shaft that sticks out of the transfer case, and pulled the old oil seal out ready for the replacement. The problem I have is that the selector shaft can move about half an inch up or down when it's free from the linkage and it has dropped low (almost flush with the surrounding housing with no feasible way of pulling it back up ready for the linkage reconnection. The position it's in now seems to put the transfer in the low range.

I have tried strong magnets, hot glue stick, tweezers, small pliers etc without much luck.

Any insights will be very appreciated!!

The linkage (behind the little yellow tape mark) being disconnected.

Closer look at the linkage. The shaft is just behind it in this picture.

 

[OGBeno]

Yeah. That sucks.

@orangefj45 might have some ideas since he’s probably rebuilt 1000 of these on the side of the trail on the Rubicon.

You can try lowering the cross member that holds up the xfer case and see if that gives you enough leverage to access it from above.

 

[Tigris]

Yeah. That sucks.

@orangefj45 might have some ideas since he’s probably rebuilt 1000 of these on the side of the trail on the Rubicon.

You can try lowering the cross member that holds up the xfer case and see if that gives you enough leverage to access it from above.

Thank Onur, good tip.

I also found a an old thread from another unfortunate soul at the 80s section with the same dilemma, there was some talk about taking the PTO cover off, using a long pry bar with a borescope taped to it. Damn. I have to get on a 1000 mile trip Tomorrow!

 

[Tigris]

A look into the belly of the beast...

Took the PTO cover off. I think you can see the fork down there. I'm gonna try propping the shaft up with something. SMDH

 

[Tigris]

Cross member dropped 2"

That gave me a little better access in places and a little worse access in others.

 

[Tigris]

Holy hell!
Took a lowered cross member, PTO cover off, 15" pry bar, borescope, and magnets to pull the bastard up!

I still have to find a way to secure it while I reconnect the bellcrank linkage to it. I am open to suggestions!

The magnets still attached in picture

 

[Tigris]

Somehow, the borescope trick worked! The truck is all buttoned up now and all is well. The second biggest challenge was how to keep the selector shaft from falling back into the transfer case while trying to affix the bellcrank linkage back on the top of it. For everyone's future references, that was achieved by wedging the pry bar through the PTO port and rummaging around until you feel small bumps on the selector shaft held with one hand via magnets.
Once you find that sweet spot on the side of the selector, it will hold precariously in place, then you should have the bellcrank disconnected from the rest of the linkage to allow for fettling, and once you have the bellcrank secured on the shaft, you are on your way out of this mess.

Thanks for the help folks!