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Old 04-14-2009, 10:14 AM   #1 (permalink)
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Tcase getting stuck in between 2WD and 4H...????

Okay so my tcase shifter keeps getting stuck in between 2WD and 4H.....and makes a bad grinding noise and truck will not move anymore till I pull shifter and then if I try to drive truck again it gets stuck again....??

I put a NEW shifter sheet in.......still gets stuck.....

I even put in a used samurai Tcase to see if maybe my case was dead....but still does the same thing with new shifter sheet as well...????

WTF!!! Please help

Weird thing is, if I put it in 4L I can drive no problems.....
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Old 04-14-2009, 12:29 PM   #2 (permalink)
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worn front out put maybe?
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Old 04-14-2009, 12:47 PM   #3 (permalink)
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maybe the front output synchro gear is cracked or broken. normally caused by a crack in the shaft the synchro rides on. mine wouldn't go into 2wd when I did this karnage. 4low worked, just front tires didn't pull.

Last edited by 2slo4u; 07-26-2009 at 04:55 PM.
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Old 04-14-2009, 12:57 PM   #4 (permalink)
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maybe the front output synchro gear is cracked or broken. normally caused by a crack in the shaft the synchro rides on. mine wouldn't go into 2wd when I did this karnage. 4low worked, just front tires didn't pull.
that is my other thought.. but hoping for the easy road out for him.
another worstcase could be that bearing retainer on the front output housing broke/ cracked and the out put has a broken nipple letting the front shaft to be cocked

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"It's my belief that someone with a Samurai ran over a Gypsy's dog or something years ago, and he laid a curse on the whole lot."
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www.ruffstuffspecialties.com
www.zukeviltwin.com
www.polyperformance.com
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www.trailtough.com
www.lowrangeoffroad.com

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Old 04-15-2009, 01:36 AM   #5 (permalink)
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but would it be weird that both the cases that I put in have the same problem???
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Old 04-15-2009, 02:07 AM   #6 (permalink)
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are you accidently useing a trany shift sheet in a tcase?
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"It's my belief that someone with a Samurai ran over a Gypsy's dog or something years ago, and he laid a curse on the whole lot."
-UZI 9mm
thanks to:
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www.kore4x4customs.com
www.ruffstuffspecialties.com
www.zukeviltwin.com
www.polyperformance.com
www.DEEPWOODSEXTREME.com
www.trailtough.com
www.lowrangeoffroad.com

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Old 04-15-2009, 08:17 AM   #7 (permalink)
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but would it be weird that both the cases that I put in have the same problem???
just re-read that.

are you centering both slides before dropping in the t/c shifter?
how do the cases act on the bench?
does the front axle and hubs turn fine?

when you go from 2wd to 4wd, the lever slips a coupler over gear I snapped onto the gear supa posted. pretty simple.

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Old 04-15-2009, 09:55 AM   #8 (permalink)
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Quote:
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are you accidently useing a trany shift sheet in a tcase?
Hummmm....I put one in the tranny aswell couple months ago....will check for shits and giggles.....

Quote:
Originally Posted by 2slo4u View Post
just re-read that.

are you centering both slides before dropping in the t/c shifter?
how do the cases act on the bench?
does the front axle and hubs turn fine?

when you go from 2wd to 4wd, the lever slips a coupler over gear I snapped onto the gear supa posted. pretty simple.
-Yes, slides are centered before dropping in shifter....
-The case when into all gears fine, had a little trouble getting in into 4L. Been sitting for a while with no oil in it....????? Seems to be okay now that its in the truck with oil in her.
-hubs go from lock to unlock Normally.

I drove home the day it broke with front hubs locked and in 4L. And I could tell front axle was working......hard to steer in 4wd.
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Old 04-15-2009, 02:11 PM   #9 (permalink)
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So I looked at a couple things today.......

-4L now pops out and grinds too...
-shifter sheet is the correct one....
-When case in neutral it is making a continuous noice. like a bad vibration noise when the little shaft is spinning, when tranny in neutral and foot OFF clutch....

So I put truck in first gear, case in 2wd...try to drive forwards and pop, it gets stuck in between 2wd and 4H. If I put in first gear and case in 4H and try to drive forwards, pop, it goes into neutral. If I put it in first gear and case in 4L and try to drive forwards, pop, it stuck jammed in between 4L and neutral.....

WTF!....

I understand what you guys are saying about....
-bearing retainer on the front output housing broke/cracked and the out put has a broken nipple letting the front shaft to be cocked
-front output synchro gear is cracked or broken
but it just seams weird that my original case and a case that I just bought used would have the same problems????
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Old 04-15-2009, 07:15 PM   #10 (permalink)
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Quote:
Originally Posted by Lil' lucifer View Post
So I looked at a couple things today.......

-4L now pops out and grinds too...
-shifter sheet is the correct one....
-When case in neutral it is making a continuous noice. like a bad vibration noise when the little shaft is spinning, when tranny in neutral and foot OFF clutch....

So I put truck in first gear, case in 2wd...try to drive forwards and pop, it gets stuck in between 2wd and 4H. If I put in first gear and case in 4H and try to drive forwards, pop, it goes into neutral. If I put it in first gear and case in 4L and try to drive forwards, pop, it stuck jammed in between 4L and neutral.....

WTF!....

I understand what you guys are saying about....
-bearing retainer on the front output housing broke/cracked and the out put has a broken nipple letting the front shaft to be cocked
-front output synchro gear is cracked or broken
but it just seams weird that my original case and a case that I just bought used would have the same problems????
they are such common problems you may just be unlucky .and have simmilar problems in both cases .. i would open the one you have out and check it to isolate the issue
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"It's my belief that someone with a Samurai ran over a Gypsy's dog or something years ago, and he laid a curse on the whole lot."
-UZI 9mm
thanks to:
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www.kore4x4customs.com
www.ruffstuffspecialties.com
www.zukeviltwin.com
www.polyperformance.com
www.DEEPWOODSEXTREME.com
www.trailtough.com
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Old 04-15-2009, 07:53 PM   #11 (permalink)
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will do....get back ya soon......
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Old 04-15-2009, 08:26 PM   #12 (permalink)
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so took the rear nose off.....this what I gots so far....

Nothing I guess......
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Old 04-15-2009, 08:51 PM   #13 (permalink)
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here's the second half............????
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Old 04-15-2009, 09:13 PM   #14 (permalink)
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ok i'm lost .. .. you need to look into this
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"It's my belief that someone with a Samurai ran over a Gypsy's dog or something years ago, and he laid a curse on the whole lot."
-UZI 9mm
thanks to:
www.longfieldsuperaxles.com
www.kore4x4customs.com
www.ruffstuffspecialties.com
www.zukeviltwin.com
www.polyperformance.com
www.DEEPWOODSEXTREME.com
www.trailtough.com
www.lowrangeoffroad.com
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Old 04-15-2009, 09:24 PM   #15 (permalink)
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ok i'm lost .. .. you need to look into this
FRICK!!!! I pull it apart and you say your lost.....

the only thing I did notice, but not sure if this is normal was this bearing is loose. front to back.....
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Old 04-15-2009, 09:49 PM   #16 (permalink)
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Hmm seems weird being 2 different Tcases & all.. Tell me this. Do you put your clutch in when you shift your Tcase? Reason why I ask is that on my rig my throw out bearing is going out so when my foot is off the clutch and my tranny is in neutral the outputshaft from the tranny going into the tcase still spins & as a result i have a hard time putting the Tcase in gear. So i put the clutch in wait till it stops spinning & then change tcase gears.
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Old 04-15-2009, 10:14 PM   #17 (permalink)
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Hmm seems weird being 2 different Tcases & all.. Tell me this. Do you put your clutch in when you shift your Tcase? Reason why I ask is that on my rig my throw out bearing is going out so when my foot is off the clutch and my tranny is in neutral the outputshaft from the tranny going into the tcase still spins & as a result i have a hard time putting the Tcase in gear. So i put the clutch in wait till it stops spinning & then change tcase gears.
Always push in clutch before shifting into 4wd.

My tranny to Tcase shaft only spins when tranny in newtral and Tcase in neutral. But in this position their is a weird vibrating sound.
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Old 04-15-2009, 10:30 PM   #18 (permalink)
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okay now you got me thinking....

Disregard the Tcase poping out of gear thingy....

I just put my Tcase into 2wd and put tranny into 1st and tried to drive it, it made a little popping noise and then the grinding sound. Once the grinding noise starts the truck will not move anymore. But Tcase is still in 2wd...

Ummmm......
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Old 04-16-2009, 07:49 AM   #19 (permalink)
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by chance, is there a small pink bike wrapped around your rear driveline? That t/c case needed to come apart with the mud sledge that came out.

I'd think you could jackstand the rear axle, throw the t/c and tranny in neutral and spin the drive train.

rear locker?
r/p lost teeth?
u-joints?
excessive lift binding drive lines at the t/c?

no noise on on jack stands?

trannys lost its bearings or the clutch pilot bearing?

you watch, it'll be something stupid like a little blue bike or one of those battery operated heeps wrapped around the axle.
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Old 04-16-2009, 09:21 AM   #20 (permalink)
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Quote:
Originally Posted by Lil' lucifer View Post
Okay so my tcase shifter keeps getting stuck in between 2WD and 4H.....and makes a bad grinding noise and truck will not move anymore till I pull shifter and then if I try to drive truck again it gets stuck again....??

I put a NEW shifter sheet in.......still gets stuck.....

I even put in a used samurai Tcase to see if maybe my case was dead....but still does the same thing with new shifter sheet as well...????

WTF!!! Please help

Weird thing is, if I put it in 4L I can drive no problems.....
It seems you're chasing the wrong Drivetrain component. Try draining the REAR diff. and see if any metal drains out with the oil. You might have damaged the spider gears and/or diff.gears.

Freestanding (4-jack stands) to test won't work because there isn't a load on the system.
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Old 04-16-2009, 09:59 AM   #21 (permalink)
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the grinding sound does sound alot like stripped ring and pinion......but it was my case poping out, so thats what I thought was the problem.
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Old 04-16-2009, 10:27 AM   #22 (permalink)
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while you have the case apart check for a bent shift fork. worn bearings can also allow the shafts/gears to deflect away from each other, this screws up the engagement angle of the gear teeth. this will cause a tranny or t-case to pop out of gear. it also wears out the gear teeth, compounding the problem. when you drained oil from the t-case were there any chips or general metallic contaminants(like fine,glittery dust)?
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Old 04-16-2009, 10:39 AM   #23 (permalink)
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It seems you're chasing the wrong Drivetrain component. Try draining the REAR diff. and see if any metal drains out with the oil. You might have damaged the spider gears and/or diff.gears.

Freestanding (4-jack stands) to test won't work because there isn't a load on the system.
sure.
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Old 04-16-2009, 10:43 AM   #24 (permalink)
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if the truck was in the air with tranny in gear and Tcase in 2wd, I shouldn't beable to spin the rear tires right. But If I could.....R/P......???
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Old 04-16-2009, 10:54 AM   #25 (permalink)
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unless all teeth are gone, you still should have some engagement. however you may notice excessive slack or grinding. go to neutral and see how smoothly things turn. you still may have some problems in there. the bearing slack/alignment issues i mentioned in my previous post can cause big trouble in a diff too. you may be unlucky enough to have problems in both diff. and t-case. hope not. of course it's a good excuse to step up to the next level. more than one zuk owner has been pushed in this direction. you know the rationale:got spend money to fix it, might as well upgrade now!
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