Transfer case shifter jumping out/adjustment issues

[3pits]

I am not new to Land Cruisers, but new to the 80 series and new to messing with transfer cases other than changing seals and gaskets.

I recently bought a semi rough 1994 Fzj80 with 171k on the clock.

Getting it back to baseline I noticed the drive shafts were not indexed correctly and finally surmised the transfer case has been removed and TIG welded on lower DS flange/case where the bolt goes through holding the front and back halves together.

I do not know the original reasons for the PO taking it out or how the case was broken, I suspect it was leaking and the mechanic broke the case. Anyhow it is a good TIG weld and is not an issue. The nose cone seals are new and there is some orange RTV coming out of the mating faces.

From inside I moved the transfer case shifter to the L position and the CDL/ABS lights illuminated as they should. As I start to move the vehicle forward (yes it is in the lower gears) the shifter pops forward and the transfer case goes to neutral... I can hold the shifter in the L position but can feel it wants to continue to jump out....

After searching and searching I cant find anyone else having this issue.
One thread indicates adjusting the shifter rod from the shifter to the transfer case shifter coming out of the transfer case by loosening the 12 mm nut and moving it some.

I tried it in a few different locations, but only the original location got me to start the engine and be in H gear...there is not enough adjustment slot to put it where I think it needs to be.

BUT, when I disconnected the shifter linkage rod from the transfer shift lever on the case and move it there are distinctive detent/dimple/catches for H and N, but after the N spot there are 4 more detents where I would imagine there should be just one for L...... it is almost like the transfer High/Low shaft has more dentents than it is supposed to, or the inner transfer shift lever is installed incorrectly....

Anyone have any ideas what to do to fix this? What is causing this?

 

[azTony]

Check the motor mounts and the AtC case mount maybe? Sounds like you have already dove into the adjustment issue.

 

[3pits]

The mounts seem fine, no obvious cracks or separations. The engine does not twist enough for the linkage to bind or hit the transmission tunnel.

 

[jonheld]

when I disconnected the shifter linkage rod from the transfer shift lever on the case and move it there are distinctive detent/dimple/catches for H and N, but after the N spot there are 4 more detents where I would imagine there should be just one for L...... it is almost like the transfer High/Low shaft has more dentents than it is supposed to, or the inner transfer shift lever is installed incorrectly....

This sounds like you are moving the transmission shift linkage and not the transfer case shift linkage. The transmission linkage is adjustable. The transfer case is not.

 

[3pits]

now wouldn't that be some cheeeet... I will double check it.. I guess using my coleman lantern and working on this after 14 hour work days, I could be doing this.

 

[3pits]

okay you were right, odd how the transmission shifter comes thru the floor closer to the passenger seat, but is closer to the drivers seat in the cabin... a d'oh moment to say the least...

but what could be causing the transfer case to jump out of gear?

I am guessing I have to pull it off and take it apart if I want L gears...

 

[Gumby]

You can pop the linkage off the shifter, it's just a clip, and manually push on the linkage rod to see if it will go further into low. If it does, give it a spin and see if it stays. If it does its a linkage problem. If it does not its either a detent ball or assembly problem. I'll check tomorrow and see if there's a detent ball you can access.

 

[3pits]

good idea, thanks.

 

[Gumby]

There is a detent ball and spring. It appears to be located under the center diff lock actuator. If you pull the actuator and the gear it engages there is a allen head plug with the spring and ball under it.

Not the easiest thing to get to when the transfer is in the truck.

 

[3pits]

I will have some time monday to tinker with it, thanks again for the ideas.

I am not sure about the gear your are referring to, but I will give it a try..

 

[3pits]

okay, I am back at it, I removed the allen head bolt, and cannot find the spring or ball,,, my gues after pouring over diagrams is that the ball is in front of the shift rod, thus preventing the rod from going all the way forward and completely engaging the gears, thus the popping out of low gear...
in the fj62 the shaft goes into a hole that has an access from a press plug on the end, the 94 80 t case is completely cast in this respect, to accept the shaft, I cannot get to the ball from removing the allen head bolt.

it appears I have to disassemble the t case and gearing to get what ever is in the recess out.. unless I can remove the front cone, which houses the recess.. is that possible? to remove the front cone by itself?

 

[Atwalz]

I am running into same issue. 4l on the tcase jumps to neutral. I had @eurosonic aka stellar regear TC with marlin crawler low range gear swap and 10% underdrive high range. I have not wheeled it since the gear swap. I took to four wheeling few weeks back and 4 low keep jumping to neutral. No issue in 4H. I am touching base with Stellar to look into it.

Edit for diagnosis:

It was shifter boot that was causing jumping. I disconnected shifter linkage in 4 low and drove around block. Gear did not jump. So cut both boots on shifter and connected the linkage. No issues during test drive.