Gentlemen:
As I have stated before in my posts I am putting a 2F engine and 4 speed tranny in my FJ40. I have an occasional problem with my transfer case coming out of low range when backing down a steep hill. Not enough to warrant taking it out to fix it. Now I will be attaching the four speed to the three speed tranny. So while its down and on the bench I would like to fix the transfer case. Now for the question. What is it that needs fixing? Thanks, HOOT

My guess is it would be what I think is called the clutch gear or transfer drive gear spector part #070-23A that chooses the low range or high range on the out put shaft, or could be the low output shaft itself.

In my best Dennis Miller voice
"Thats just my opinion, I could be wrong"

It is probably due to excess wear on the Lo gear bushing on the main shaft. Different years have different sizes, so make sure of the year of the case. They press in. They come oversize, so they need to be reamed or honed to correct size afterwards. It could also be wear on the clutch gear, but typically there is very little wear on the Lo range side.

There actually should be just as much wear on the clutch gear for LO as there would be HI. The gear will either be on the LO/main shaft or will be on the main shaft/HI part. The reason I said that is if it is popping out in LO is that the teeth could be sheered just a little on the LO side, then when in HI it wouldnt matter as much because it wouldnt want to be popped unto the LO side. Dont know if that made sence to anbody but me.

Any way you slice it and dice it you are going to be in there anyway to find out what is wrong. Neither part is very expensive, so you might consider just replacing all of them.

Guys, I sure appreciate your replies. I guess that just after the first of the year I will order the parts from SOR. What do you guys think, should I also buy the t-case re-build kit while I am in the case? Thanks, HOOT

I wouldnt, but thats just me. Seems I tear stuff apart all the time, and the rebuild kit just has gaskets and bearing if I remember right. I just put RTV black for gaskets and my bearings were fine. If everything is working good I would just leave it. For sure I would take it apart and fix it though, you basically have it apart just to remove it. Parts are realitivly cheep.

If it ain't broke (or worn), don't fix it, but I would expect to replace the idler gear bearings and center pin.

Hey guys, Thanks, for the information, I really appreciate your help. HOOT Murray