Transfer case won’t shift high to low - stuck in low

[sloanstavern]

Hey guys I discovered an issue with my transfer case. It appears to be stuck i in low gear. Whether it is in four-wheel-drive or 2 Wheel Dr.

‘82, Non US FJ45, 4 speed

Up on the jackstands with the transmission in neutral and the T case in two wheel high I could rotate the rear tires at the rate of 1.75 driveshaft rotations per tire rotation. When I move the shift lever into low gear the ratio did not change. There is no resistance moving the shift lever left to right to go from four wheel high to four wheel low.

2 Wheel Dr. versus four-wheel-drive does exchange properly with the shift lever. The little bit of driving I’ve done on the vehicle the revs are insanely high indicating it’s stuck in low gear as well.

Full disclosure the last time I drove this 2 1/2 years ago I only put a few miles on it and I remember the revs were quite high but maybe not this bad. It appears something is not connected on the high low gear lever internally. I’m not optimistic I can access that without dropping it out of the vehicle but welcome any thoughts.

 

[Living in the Past]

First thing take the inspection cover off and verify the high, neutral, low lever is moving.

 

[middlecalf]

I probably should take my afternoon nap before I ask this question cuz I could be really tired and not in a full state of mind, but why do you think the drive shaft rotation rate would change when nothing downstream of it changed when shifting from high to low in the transfer case?

 

[B y r o n]

You need to have someone shift the transfer case lever and someone watch the linkage from underneath to make sure everything is tight and moving as it should.

 

[peesalot]

I agree that you should remove inspection cover and verify shift fork movement.

 

[sloanstavern]

I probably should take my afternoon nap before I ask this question cuz I could be really tired and not in a full state of mind, but why do you think the drive shaft rotation rate would change when nothing downstream of it changed when shifting from high to low in the transfer case?

That was a very polite way of saying I am a knucklehead

Just because it’s data doesn’t mean it’s good data……..

 

[sloanstavern]

You need to have someone shift the transfer case lever and someone watch the linkage from underneath to make sure everything is tight and moving as it should.

Thanks, I am able to move that by hand and while it rotates the shaft nothings happening internally

 

[sloanstavern]

First thing take the inspection cover off and verify the high, neutral, low lever is moving.

I pulled off the inspection cover after I drained the fluid in the biz visibility is limited not really sure what I’m looking for here’s the best shot I could get of the far end of the transfer case.

The shift linkage is rotating the hi-lo neutral arm but it doesn’t appear that anything is happening inside the transfer case.

The 4wd-2wd functions properly

 

[Godwin]

I pulled off the inspection cover after I drained the fluid in the biz visibility is limited not really sure what I’m looking for here’s the best shot I could get of the far end of the transfer case.

The shift linkage is rotating the hi-lo neutral arm but it doesn’t appear that anything is happening inside the transfer case.

The 4wd-2wd functions properly View attachment 2947321

In your photo you can see the notch in the shift fork. The H-L shift linkage has dropped too low to engage this notch. You probably need a washer on the outside of the case to pull the shift linkage higher so that it will engage the shift fork. You may be able to accomplish this without splitting the t-case.

 

[sloanstavern]

In your photo you can see the notch in the shift fork. The H-L shift linkage has dropped too low to engage this notch. You probably need a washer on the outside of the case to pull the shift linkage higher so that it will engage the shift fork. You may be able to accomplish this without splitting the t-case.

Perfect timing, I just came in from playing around with it and discovered the same thing I wedged the control arm up so that the pin was engaged and was able to change gears, what a relief it looks like I only need a quarter inch or so of spacing and I can access the control arm reasonably well thank you so much for the confirmation I’ll give it a shot .

BTW- that access window was not designed for a near sighted guy with a size 8 melon that’s a tight fit…….

 

[Living in the Past]

I pulled off the inspection cover after I drained the fluid in the biz visibility is limited not really sure what I’m looking for here’s the best shot I could get of the far end of the transfer case.

The shift linkage is rotating the hi-lo neutral arm but it doesn’t appear that anything is happening inside the transfer case.

The 4wd-2wd functions properly View attachment 2947321

I was talking about the inspection cover in the transmission hump. The one on the side of the transfer case is to install a PTO. I have never torn a split transfer case down even though I have a few. The fork for the collar to shift between high and low appears to be harder to install. One piece transfer case there is a plate on the top of transfer case. If the fork is off on a split case may require a tear down to install it right.

 

[sloanstavern]

I was talking about the inspection cover in the transmission hump. The one on the side of the transfer case is to install a PTO. I have never torn a split transfer case down even though I have a few. The fork for the collar to shift between high and low appears to be harder to install. One piece transfer case there is a plate on the top of transfer case. If the fork is off on a split case may require a tear down to install it right.

Got it thank you, this tub does not have a full transmission hump cover it’s the small access panel I didn’t take that apart yet that might make things simpler.

I can access the external pivot arm and slip some washers underneath it what should solve the problem however if I see this correctly it looks like that internal arm could drop into the transfer once I disconnect the pivot arm. Is that correct?

From this photo I know I couldn’t access the top through the transmission hump port and they’re also it’s not a inspection panel from that side

 

[Godwin]

I can access the external pivot arm and slip some washers underneath it what should solve the problem however if I see this correctly it looks like that internal arm could drop into the transfer once I disconnect the pivot arm. Is that correct?

This is correct that once you disconnect the linkage that the internal shift arm could drop into the case. If that happens you may be able to lift it out with a magnet, add a washer, and reconnect. Otherwise the rear the t-case needs to come off.

 

[3_puppies]

as preventative from the arm dropping into the case, use a long bar or similar and wedge underneath the arm thru the pto cover, where you took the pic above.

 

[Living in the Past]

Show a washer above the seal which puts it on the outside. Part number 94612-11300. Should be easy enough to do. Just be sure the lever is in the collar when you install it. Think you will find the tunnel inspection cover off will make it easier to get at. If you have rebuilt the transfer case would install a new seal while your it.

 

[B y r o n]

Maybe the diagrams in this thread will help.

 

[Ernboto]

My High/Low lever has dropped into the transfer case. I have tried pulling it back out with a strong magnet without success. I have tried poking around through the inspection cover without success. How screwed am I? Has anyone had success using a lever to push it back up?
Edit: I should mention I'm working on an '86 FJ60