We just got back from bassi on sunday night and we parked the zuk. THe next day we decided to move this old ford 250 that has no axles on it. we put it in four low and put it in reverse. we gave it a yank and decided it was too heavy woth out some help. WE went to take it out of four low and couldn't get it to go into 2H. WE tried to get it back into 4L or 4H but no dice. Its jsut stuck now in nuetral. we took a look at the fluids all check out ok. pulled the shifter it looks slightly worn but well within limits. Without opening up the t-case how can we figure out whats wrong with it.

Probably a long shot, but check to see if you tweaked the t-case arms. If they are bent much, I know it will pop out of gear like crazy. Might not cause your problem, but is worth a try.

My buddy had a similar problem. He broke some $2 part in the t-case and was stuck in the boonies for a couple of hours. He finally discovered that if he pulled up on the t-case gear shift and held it in position, he could shift and keep it gear to get home. I am not sure what the problem was exactly, but it was a cheap and easy fix. Worth a try.

Actually its not that it won't stay in gear its that you can't even find the gear to get it into. there was no noise like it broke and it was working fine a moment earlier. THe t-case mount was missing a bushing but we fixed that and it wasn't helping. we are going to go see if the pull up thing works.

Tcase shifter sheet. I think its a 4$ part. Unscrew the knob, take off the boot, get under there & pull off the rubber boot on top of where the shifter goes in- push in on the slotted metal ring and turn it clockwise. it'll pop out.. pull out the bushing. this is the shifter sheet. I just fought this little beauty sunday.

defiantley the shifter sheet like he said... suzukijohn has them as well. You can for the time being yank the shifter out and get it back into gear with a screwdriver to use the sami again till the new sheet is in

OK then I took I couldn't do anything with a screw driver. I took the tcase apart real quick (like only five minutes out, fix and in agian) And I found the two rods with the notches in them were out of alignment. we called a shop and they said this happens sometimes if you jerk the shifter too hard at an angle before bring it down far enough before. So I corrected that and stuck the shifter back in. I went into 2h no problem and back out agian. I left it in 2H for now because I need to be able to get to school in the morning. I also found that my tcase mounts were going bad so that might have been a contributing factor. I will test and see if I have all the other gears tomorrow after school. thanks for the help guys. I might need to do more work on it yet so stay tuned.

shifter sheet. i know their service sucks, but RR sells a lifetime warranty tcase sheet for $14:beer:

yea dont buy them from roacky road.... suzukijohn has the exact same part and hell prioity mail it to you

I was at bassie this weekend....Were you in a blue zuk?

Yeah, we were in the blue and grey zuk. My buddy was the red headed guy who was driving on the way in and I was the guy in tshirt and shorts. What were you driving? I think we are going up agian this weekend. You?

I had the huge snow camo zuk...

Shifter Sheet... Suzuki part #: 29541-80051.

Just ordered one. It is in front of me. It's the same problem I have. I pulled my t-case out and the bushing was significantly more collapsed that when I put it in about 24 hours before. How? I dunno. Why? I dunno.

But, this is suposed to be the fix.

Tom

You can buy a better Urethane sheet on Ebay for 10 bucks:)