Engine/Transmission (1998.5 - 2002) Transfer case shifting

[CGPike]

I sure could use some help. I have a 2000 with 5 speed that I have had a problem with for quite a while, and can't find any postings that seem to give me any suggestions or direction. The transfer case shifts normal and easily into 4wd lo, but very difficult to get back into either neutral, 2wd hi or 4wd hi. This has happened 4 times now, each time it is more difficult to get back into above gears. Once past neutral, shifts easily between 2 hi or 4 hi. The last time I shifted into 4 lo was over a year ago. I am in the process of putting in a new clutch so I got brave and tried one more time into 2 low... ... ... and now it is stuck there. It moves partially, not quite into neutral but will not go beyond there. It is a very solid stopping point. I am going to have to buy another t-case or get brave and rip this one apart to see what is holding it up. Really hate to do that, but I need to fix this now, before I put the truck back on the road. Any suggestions would be greatly appreciated!

 

[Joe Mc]

Not the optimum way to get out of 4lo but, have you tried easing on the throttle then as you let off try pulling out of 4lo? Then go into either 4hi or 2hi. Sounds like something isn't right in the t-case though, as you already surmised it shouldn't be this difficult. Anyone else out there have an idea?

 

[CGPike]

I have driven 4 wheelers a lot of years, and I know how they can be stubborn and some have their own quirks, but this bad boy has a problem inside the t-case. I am hoping for someone to suggest what I should look for before I tear into it. I now have the t-case on the bench and it still won't shift back even as far as neutral. You pull it partway back from 4 lo and of course it is not properly engaged,... ... ..... but it will be in 2 hi. I had this happen on one occasion so I proceeded to drive it like that so I could get home if possible. After a few miles the transfer case popped into neutral, and then I was able to shift it normally. After that I never tried it again until the other day, just before I pulled it into my shop to do the clutch job.

I assume it will be something along the lines of a bent fork or maybe some sort of gauling on the shift linkage inside the t-case. I have never had one of these apart and I have not been anxious to do so.

I am pretty sure I will tear it apart today and will post up anything I find.

Anyone else have thoughts before I begin?

 

[SnoKing]

Try backing in a circle while you hod pressure on the lever. It you have it bond up, then that will release the bind. Does it drive ok on dirt in 4 wheel drive? Did someone change the rear gears and not the front?????? SNOKING

 

[CGPike]

I tried back and forward with pressure on lever, (and also just on and off the clutch trying to put load and remove load, didn't make any differance), before I removed the t-case. It is solid stoppped inside the t-case. Thanks for the ideas!

 

[SnoKing]

I tried back and forward with pressure on lever, (and also just on and off the clutch trying to put load and remove load, didn't make any differance), before I removed the t-case. It is solid stoppped inside the t-case. Thanks for the ideas!

Back and forth with the wheels hard over to change the distance traveled front to back? SNOKING

 

[CGPike]

GOT IT! Well I bit the bullet and tore into the Transfer case. I found a snap ring had came out of it's groove down in the area of the low range. I don't know the name of the parts, I just pretty well know how to carefully take things apart and usually get them back together. Thanks for any suggestions you had... ... ... . now I just have to get all put back together. Parts should all be in over the next couple of days.