Transfer Case Failure x 2

[SCF Truck]

This is bothering me. If it jumped out of gear in 4 hi or 4 low, I would assume linkage adjustment. But, since 2hi is not on either end of the shifter travel....???
The shift lever has nothing to do with where the fork position is, it just moves the linkage/fork to the next detent. If 2hi was not engaging the detent, then the linkage would need to be so far out of adjustment that neutral, or 4 hi would also not be available.

Happened in 2H at about 50 mph. Both times. I can say this, that the loaner Ram also a new 2500 4x4 manual txfr case works fine. It also has smoother txfr case shifting action than mine.

So here's a question, is this truck worth keeping if I can verify the shift linkage is set correctly? If the linkage is correct then the question is what else is causing this? A defective engine transmission mount? I really dont want a 3rd on the road out of area failure.

 

[TFucili]

History has proven that t-case to be very stout and reliable. If you can get to the root of it, you'll have a good truck, and it will very likely be less of a financial hit than dumping it. Sometimes it is worth the hit for the peace of mind, though. I have been in your shoes far too many times.

 

[jgillott]

Happened in 2H at about 50 mph. Both times. I can say this, that the loaner Ram also a new 2500 4x4 manual txfr case works fine. It also has smoother txfr case shifting action than mine.

So here's a question, is this truck worth keeping if I can verify the shift linkage is set correctly? If the linkage is correct then the question is what else is causing this? A defective engine transmission mount? I really dont want a 3rd on the road out of area failure.

I think your best bet is to get your truck back from the dealer and then contact a lemon law attorney in your state. If you sell your truck right now, you are on the hook for the depreciation, etc. These are the exact situations why lemon laws are in existence.

Know your rights under the law before you make any decision to sell or trade on another vehicle. You could potentially save yourself thousands of dollars in the long run.

 

[Wayne M.]

The shift lever has nothing to do with where the fork position is, it just moves the linkage/fork to the next detent. If 2hi was not engaging the detent, then the linkage would need to be so far out of adjustment that neutral, or 4 hi would also not be available.

I don’t know for sure weather or not that shifter has a gate or some other reference that could interfere with the fork detents.

 

[RVTRKN]

Not that I repair them every day or even wrench for a living, I would have after the second before running it with a load, check the transfer case ranges by just shifting into all ranges to check the new TC for operation. That should have been a clue that the shifter linkage was not correct or if there was play that was suspicious.

 

[NIsaacs]

So here's a question, is this truck worth keeping if I can verify the shift linkage is set correctly? If the linkage is correct then the question is what else is causing this? A defective engine transmission mount?

I don't think a bad engine or transmission mount could change the shifter position. The shift lever is bolted to the transmission/t-case, so any excess movement of the engine/transmission, the shifter would move with it, not pull it out of gear.

I am running out of ideas....

 

[SCF Truck]

I don’t know for sure weather or not that shifter has a gate or some other reference that could interfere with the fork detents.

I believe there is a plastic detent on the floorboard for the shifter to help hold it in place. Anyone know for certain?

 

[NIsaacs]

I don’t know for sure weather or not that shifter has a gate or some other reference that could interfere with the fork detents.

I don't think so but I don't know for positive. My '01 don't. The shift rail/fork/detent does all the work/positioning, the shift lever just gets it there. The movement of the shift lever is just straight forward or back.

 

[NIsaacs]

I believe there is a plastic detent on the floorboard for the shifter to help hold it in place. Anyone know for certain?

If there is, then yes, adjustment would be critical and both detents would have to match.

 

[SCF Truck]

Research your state's lemon law. Keep records of your weigh station visits.

If the lemon law in your state says 3 fixes and you can pursue lemon law buy-back..... Just drive it until it blows again and declare lemon law.

I have a copy of Maryland Lemon Law. It's straight forward. Step 1 is to attempt resolution at the lowest possible level; dealer followed by Manufacturer and if still unresolved submitting a claim to the state attorney general's office.

 

[Ozymandias]

Yes a binding shift lever could cause that problem, if the Drivetrain underneath works around driving and the lever itself refuses to do that movement to, then it couls shove out the gear.

I do not think that there are engine or transmission mounts are not properly at that age of vehicle.
But a shift lever that is binding, that could be possible because it is cheap part.

As you say, the shift lever in the loaner hat another feeling while shifting - that is highly suspect.
They should feel the same, absolutely the same as it is an identical setup, entirely.

And, you had 2 different TC cases (not a repaired unit) below on your truck, so the TC itself is out of the game for the feel of the shifting itself, the lever is the only thing that stayed..

Conclusion - I blame the lever for that failure.

 

[SCF Truck]

Yes a binding shift lever could cause that problem, if the Drivetrain underneath works around driving and the lever itself refuses to do that movement to, then it couls shove out the gear.

I do not think that there are engine or transmission mounts are not properly at that age of vehicle.
But a shift lever that is binding, that could be possible because it is cheap part.

As you say, the shift lever in the loaner hat another feeling while shifting - that is highly suspect.
They should feel the same, absolutely the same as it is an identical setup, entirely.

And, you had 2 different TC cases (not a repaired unit) below on your truck, so the TC itself is out of the game for the feel of the shifting itself, the lever is the only thing that stayed..

Conclusion - I blame the lever for that failure.

Photo enlarged of shift lever coming through the floorboard. I'm out of town so dont have access to the loaner truck to study this design.

 

[NIsaacs]

The lever does appear to be attached to some funky plastic gizmo that may be attached to the floor, jeezzz...

 

[TFucili]

If possible I'd isolate the t-case from the linkage. Work the shifter back and forth to feel for binding, or springiness in the mechanism, and isolate from there.

 

[Wayne M.]

If possible I'd isolate the t-case from the linkage. Work the shifter back and forth to feel for binding, or springiness in the mechanism, and isolate from there.

I’ve been wanting to suggest that once it’s in 2wd, just disconnecting the linkage altogether just to see.

 

[Wiredawg]

I replaced that plastic piece 2 or 3 times on my 03 2500 an twic on my former 09 4500. when it craps out, all it does is prevents you from shifting the xfer case.
FYI, a carried an extra one in each truck just in case. I guess the vibration just eats 'em up and spits em out.

Ron

 

[Ozymandias]

Photo enlarged of shift lever coming through the floorboard. I'm out of town so dont have access to the loaner truck to study this design. View attachment 111340

I'm the only one that thinks that this bushing looks something, i don't know, worn out?
And that the metal parts looks like it has gone through a gravel pit?

 

[jhenderson]

The closeup could be throwing you off. The rounded front of the bushing is fresh looking. The flat back looks like many I’ve seen. A little rough and unfinished. The lever and bolt aren’t cad plated so the also look a little rough but not out of the ordinary as far as I’m concerned.

 

[TFucili]

The angle of the photo makes it look like the shift arm is against a piece of weatherstrip or something, but it's probably just the perspective.

 

[sag2]

This is bothering me. If it jumped out of gear in 4 hi or 4 low, I would assume linkage adjustment. But, since 2hi is not on either end of the shifter travel....???
The shift lever has nothing to do with where the fork position is, it just moves the linkage/fork to the next detent. If 2hi was not engaging the detent, then the linkage would need to be so far out of adjustment that neutral, or 4 hi would also not be available.

I agree, this does not add up. This is a two minute verification with a creeper. Shift TC to 4 HI, slide under truck, pull linkage off TC and make sure the shift lever is in the 4 HI detent position. If it isn't return to dealer and show them. If it is, it currently isn't the adjustment (but it could have been). If it is adjusted correctly hook up your trailer and video the same conditions it failed on last time. You will either confirm you have a reliable repaired truck, or your third repair for the LL.
This is turning into a way more complicated situation than it has to be. Take the truck, it's still yours. Until the arbitrator says to repurchase or not to repurchase you might as well use it.