Transfer Case Stuck in 4x4; help!
Junior User
Joined: Jan 2004
Posts: 62
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From: Portsmouth, NH
There is a ball bearing holding the gear in place on the shaft, you have to slide the gear towards the case, remove the ball and then you can remove the gear. I dont remember if there is something preventing the gear from sliding, like a snap ring or something (dont think so), but if there is you should be able to see it.
Post Fiend
Joined: Jan 2004
Posts: 5,377
Likes: 2
From: Elkhart IN
try moving the shift arm back and fourth a couple of times, its the chain thats holding you back, you have to take the (crap i can think of the word, is the thing the driveshaft bolts to) for the front drive shaft off, and let the shaft go through the case.
Junior User
Joined: Jan 2004
Posts: 62
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From: Portsmouth, NH
Im not sure where you are in the teardown, but the back half comes off by itself, leaving all the mechanicals inside. The back cover is on the floor in this pic. And on mine, I did have to take the speedo gear off, it hit the output shaft bearing in the back cover.
Last edited by mociaz3; Jul 28, 2005 at 10:25 PM.
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Senior User
Joined: Mar 2004
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From: Baton Rouge
OK so I do need to remove the spedo gear. That sure is what it seems like I have to do. I got a picture of where I am in the teardown in my gallery. THe case is seperated, I just can't yet slide the halves all the way apart.
Junior User
Joined: Jan 2004
Posts: 62
Likes: 0
From: Portsmouth, NH
Is the speedo gear off? Whats preventing the halfs from seperating? Again, you have to push the speedo gear towards the case, it will snap out of its position as it releases from the ball, then you remove the ball, then slide the speedo gear off of the shaft.
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From: Baton Rouge
I got it open and the problem is, there seems to be no problem. I can shift it fine with my hand and everything seems to be working properly. I don't see anything that looks out of the ordinary. What should I be looking for?
Junior User
Joined: Jan 2004
Posts: 62
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From: Portsmouth, NH
Figure out how the shifters work, and find out what was letting it shift in and out of 4x4 by itself. Check the shift forks, especially, and the lockup hub and lockup collar. How do the gears and oil pump look? Any metal shavings on the magnet? Hows the output shaft bearing?
Post Fiend
Joined: Jan 2004
Posts: 5,377
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From: Elkhart IN
what you need to be lookin at is the lockup fork and collar. the lockup fork is the one on the rear side of the case, check for play in the arm, and the collar is springloaded, so make sure that the spring (internal) is still strong
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From: Baton Rouge
You say check for play in the arm. What arm are you talking about? The spring seems weak so I may try and replace that. Other than that, I messed around shifting the thing and everything seemed like it worked fine. As far as play goes, I don't know what movement is supposed to be there so its hard for me to determine if its good play or bad play.