Engine/Transmission (1998.5 - 2002) Transfer case ???

[BarryG]

When I use 4low it will kick out of gear. 4 hi works fine no problems. After reading in the service manual troubleshooting section it mentions worn shift forks as a cause. I have read about that being an issue on here before.

I do use 4wd but not oftenm enough to be wearing out parts in the darn thing. I would say out of the 150k on the truck less than 1k was in 4wd and probably well under 100 miles in 4low I rarely use 4low. First what is a shift fork? Second what would cause one to wear especially if it is used for 4low and it is rarely used? Third how hard of a job is it to fix? Are we talking about removing the case from the truck and doing major disection or is it a relatively easy thing once the case is out of the truck? And finally with 150k on the tcase and it having this problem should I go ahead and think about a total rebuild on it?

I have had 4wd trucks for 30 years and never had this happen before and many previous ones got used/abused one heck of lot more than this one.

 

[nps]

Barry,



The shift fork is used to slide a hub back and forth to engage the different gear settings. If it is worn it may not move the hub far enough to lock in. It isn't unique to just 4lo, so shifting the tcase will cause it to wear.



However I would adjust the shift linkage to get maximum throw toward 4lo before going inside the tcase. I've never been inside this particular case, but generally the shift forks are real easy to get at if you do go that way.



BTW - got the boots - thanks again!

 

[jrobinson2]

Check the linkage first.

Some pictures to give an idea whats inside.



Worn shift fork:

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Input gear, shift fork, and range slider, the range slider engages the teeth inside the input gear for high range:

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The range slider fits inside the low range planetary and engages the splines below the gears and above the bearing for low range.

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Exploded view

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Jared

 

[hemijustin]

i had the exact same problem when i forgot to put the bearing back in the tail housing..... 2 wheel drive worked perfect but 4X4 would kick in and out... . u might want to check the bearing and the snap rings that hold it... .