Transfer Shifter Misalignment issues

[CUSailor]

Well, I'm hopefully on the home stretch of getting this thing back together ('79 FJ40) and ran into a curious snag. When putting the transfer case shifter back in I thought it was pretty straight forward. There's only one way it can mount and it seemed to be a natural fit. My probelm though is it seems I gave myself an extra shifting position. I expected the Shifter to rest against the stop in the H2 position, I pull it down into the H4 to the right one stop to the N and one more stop to the right for L4. Instead when it's in 2WD (up position) I can move it to the left. Moving it down from the left most position gives me what I believe is H4. If I have it against the stop and move it down I get Neutral.

I don't know for sure that what I designated H4 and L4 are such in this and not reversed, but I do know that Neutral is Neutral as I was able to spin the shafts. Any thoughts on where I went wrong? The transmission case did tip over during installation, while it wasn't a hard hit, it did hit some, could that have messed it up? Overall I am not going to let this stop finishing the project as I at least know where my gearing positions are but I'd like to know what is going on.

I drew it out best I can I didn't lable things H2 H4 L4 etc. since I'm just looking at the transfer case.

 

[tjhaga]

Are you sure your shifter guide isn’t bent from dropping the transmission? Perhaps post a picture.

 

[volklflip88]

^^ Also interested with a similar issue.

 

[1911]

The little lever on top of the transfer case (that shifts from high range into low) is easily bent by applying pressure on the transfer case shift lever. The stock linkage is kind of a Rube Goldberg contraption in my opinion, with slop and leverage in odd vectors. Toyota tried too hard to get two functions out of a single lever, I think. I had similar problems (after installing an Orion case) until I ditched the stock shifting mechanism and installed twin sticks. That solved everything for me; "your mileage may vary".

Edited: here is a photo of my bent mechanism that caused me problems:

bent transfer case shift lever

• 1911
• Jan 2, 2019

 

[CUSailor]

Thanks for the replies, I forgot to tun on thread notification emails! I will be back to the garage this weekend and will snap a picture or two, though it doesn't 'look' bent I wouldn't be terribly surprised. I tried to unthread the shifter linkage long enough to get it into what I believe to be H4 at the appropriate spot (instead of N) but it won't go out that far.

I'd be interested in seeing more of your twin stick setup. I guess the other option is to bend the little lever on top back if that's what is already bent? It looks to be removable.

 

[1911]

I'd be interested in seeing more of your twin stick setup. I guess the other option is to bend the little lever on top back if that's what is already bent? It looks to be removable.

Yes, the little lever is removable. When you do remove it, be sure to clamp some vice grips on the shaft, to prevent the shaft from dropping into the transfer case and ruining your day. Likewise, be careful when re-installing the lever, not to drop the shaft into the case.

I don't have any photos of the installed transfer case with the twin sticks on it from underneath the truck, but here are some from the cab. You have a single lever for each function, both with a simple back and forth motion in a single plane. Much better geometry and simplified linkage underneath.

Twin sticks

• 1911
• Oct 31, 2018

dash and twin sticks

• 1911
• Jan 2, 2019

 

[Elfman]

1911's description of rube Goldberg contraption is pretty accurate for the factory shifting. Make sure that none of the linkage bits are bent, that all rods and the pivots are properly oriented. Mine never had a guide but it shifted as you described that yours should be shifting. i switched to the twin stick from AA when I did the NV4500 swap on my '69. I love it!!! It did require welding and bending the lever shafts and my case I had to modify the trans tunnel. Here are some pics:

 

[Living in the Past]

Yes, the little lever is removable. When you do remove it, be sure to clamp some vice grips on the shaft, to prevent the shaft from dropping into the transfer case and ruining your day. Likewise, be careful when re-installing the lever, not to drop the shaft into the case.

I don't have any photos of the installed transfer case with the twin sticks on it from underneath the truck, but here are some from the cab. You have a single lever for each function, both with a simple back and forth motion in a single plane. Much better geometry and simplified linkage underneath.

Twin sticks

• 1911
• Oct 31, 2018

dash and twin sticks

• 1911
• Jan 2, 2019

Curious what the benefit is of the twin stick verses just removing the guide off the stock setup? I assume to go twin stick on the 4/75 and later transfer case you either have tear the T case apart to replace the tab for the high/low shifter or modify the lever to go to the side instead of towards the front?

1911's description of rube Goldberg contraption is pretty accurate for the factory shifting. Make sure that none of the linkage bits are bent, that all rods and the pivots are properly oriented. Mine never had a guide but it shifted as you described that yours should be shifting. i switched to the twin stick from AA when I did the NV4500 swap on my '69. I love it!!! It did require welding and bending the lever shafts and my case I had to modify the trans tunnel. Here are some pics:

View attachment 1868505

View attachment 1868509

View attachment 1868510

View attachment 1868511

Your 69 already had the lever to the side. My 79 has a strange hybrid setup that used most of your style original shift linkage when a earlier T case was installed but still used the original 79 lever thru the floor. Even though it works well will get replaced when I have to pull the transmission.

 

[darwink1]

Curious what the benefit is of the twin stick verses just removing the guide off the stock setup? I assume to go twin stick on the 4/75 and later transfer case you either have tear the T case apart to replace the tab for the high/low shifter or modify the lever to go to the side instead of towards the front?



Your 69 already had the lever to the side. My 79 has a strange hybrid setup that used most of your style original shift linkage when a earlier T case was installed but still used the original 79 lever thru the floor. Even though it works well will get replaced when I have to pull the transmission.

The factory shifter is vague at best, the twin stick seperates the two t case functions and simplifies things. I just did the twin sticks in mine last summer and the difference is day and night.

D

 

[Living in the Past]

The factory shifter is vague at best, the twin stick seperates the two t case functions and simplifies things. I just did the twin sticks in mine last summer and the difference is day and night.

View attachment 1868726


D

I test drove a Porsche 912 back in the early eighties that I would call vague at best. Some large commercial trucks during the seventies and eighties with five speeds and two speed rear axles that were vague and took some getting use too but after that were fine. Plenty of sloppy three speed column shift Fords, Dodges and Chevys but would not call a properly adjusted Toyota transfer case shifter vague. Our fourth generation 4Runner and second generation Sequoia are a button and knob on the dash if I want simpler. I like keeping my 40 series old school. Only shifting I would do while moving is going from 2WD high to 4WD high. That is just keeping the steering wheel straight and pull the lever straight back which is the same as the twin stick. Everything else is while I'm stopped. Not driving and paying attention to how I'm shifting has never been a issue. Original or twin stick both would be easier on RHD vehicles because of the closer reach. The FJ25 is the only Land Cruiser I know of that Toyota had a different setup for LHD that moved the 2WD to 4WD lever to the left side of the transmission hump. These were a single speed transfer case with single action 2WD or 4WD, no neutral.

 

[1911]

Curious what the benefit is of the twin stick verses just removing the guide off the stock setup?

Just removing the gate still leaves you with the Rube Goldberg stock linkage that can be finicky and sloppy, especially when old. Like @darwink1 said:

The factory shifter is vague at best, the twin stick seperates the two t case functions and simplifies things.

The twin stick setup removes all the play and slop that comes with the factory setup. You can see in @Elfman 's photo that each stick acts only on one thing, either high-low range or 2WD-4WD, and that the action is direct and in a single plane. Much more efficient and positive than the stock setup.

I assume to go twin stick on the 4/75 and later transfer case you either have tear the T case apart to replace the tab for the high/low shifter or modify the lever to go to the side instead of towards the front?

The stock 2WD-4WD shift fork comes out of the nose cone with only two pinch bolts; you don't have to take off the nose cone. It is replaced with a clevis fork that comes with the twin stick kit. Easy job.

For the original poster, on my (12/79 build) 1980, I didn't need to modify anything to install the twin sticks. The existing hole in the transmission tunnel fit both sticks just fine. The provided boot just barely covers it though.