Popping out of 4WD

[MULISHA JP]

I took the rig out saturday for the first time. It did well except any time it would get under a load it would pop out of 4wd and be in 2 low. So I didnt get any good pics to post up. Anyways I searched a bunch and found out the shifter can cause the this. Well the shifter was just sitting in the t-case and it will be fixed for sure. Also found that the front input could be popping out due to worn teeth. I think thats the big issue. Just wanted to post up a pic to let the gurus check it out.



A little blurry but the teeth have flat spots on all the edges. Is this it? Im going to order the HD input, mighty kong, and new shifter bushing. Also is there a detent ball under the 4wd indicater plug? I hope this fixes it, I have a toys for tots run in 2 weeks and I would really like to make it! Thanks

[Mope]

That is actually normal for the teeth to look that way. The HD shaft looks the same, except it has wider teeth overall. It will be a nice upgrade. There is a ball under the 4wd plug that is actuated by the shift rail.

[MULISHA JP]

Its hard to see in the pic but the very end of the gear at there points is actually worn flat and some of the points are broken off. Am I on the right track? Im going to order this stuff tomorrow and I don't want to buy what's not the problem. Thanks

[purevil71]

While your in there, check you shift rails as well. A bent one will cause that problems as well.

[Baratacus]

my front shock mounts snapped last year and I wasn't aware it had happened. When I put the front end under load in 4wd, my front axle would rock forward and jam the Tcase back. The shift lever would hit the back of the hole in the tunnel and it kept kicking it out of gear. I had to replace my lower shock mounts, and then straighten the tcase bracket and re-torque it. I'm not saying your shock mounts are broken, but if the T-Case is moving from a loose or bent bracket, or a worn mount, it could be kicking it out of gear. Check to make sure your t-case is in nice and solid.

[MULISHA JP]

Thanks for all the replys everyone. Ordered some stuff today and I hope it works. Also I have to check the detent balls. One has been removed for twin sticks by the guy who put t-case gears in. I'll just put it back in if I can find one.

[autoholic]

Originally Posted by Baratacus

my front shock mounts snapped last year and I wasn't aware it had happened. When I put the front end under load in 4wd, my front axle would rock forward and jam the Tcase back. The shift lever would hit the back of the hole in the tunnel and it kept kicking it out of gear. I had to replace my lower shock mounts, and then straighten the tcase bracket and re-torque it. I'm not saying your shock mounts are broken, but if the T-Case is moving from a loose or bent bracket, or a worn mount, it could be kicking it out of gear. Check to make sure your t-case is in nice and solid.

Ouch, That must have sounded pretty nasty.

[supazuk94]

check the front output housing somtimes the bearing retainer cracks in a clean circle
in this pic you see my front out put snapped .. i see yours didn't but also look at the housing that is broken too

[Hvy_Chevy]

probably want to shim that output shaft while you're at it.

[MULISHA JP]

Thanks guys! I think it is a mixture of a lot of stuff. The front drive shaft was siezed so I'd say it was pushing and pulling on the t -case. It was missing one of the detent balls so I put a new one in. The t-case shifter was just sitting in the hole. I've got the case back together, just waiting on the "snatch" to come in and the HD input to try it all out. Should I shim the input even though the conact area is wider with the HD input ?

[Mope]

You don't need to shim it with the new shaft. We'll be waiting to see if all is fixed!

Oh, and for hell sake grease that driveshaft!! lol

[MULISHA JP]

Its a square tube front shaft. I had to heat the damn thing with a torch for about 30 minutes to get it to budge! It now has 2 grease fittings so it shouldnt be an issue. I hope to hell this stuff works. Il update on tuesday. Have to work all weekend. Again thanks for all the help guys! This is way better than the Jeep forum for sure!!!!!

[Mope]

Good luck, and have fun!

[M.Martian]

Might not be the case here, but after the first time I took mine out for more than just a quick test I ended up with it popping out of gear constantly.

The problem ended up being the tcase arm twisted due to the lower gearing. When you would hit the gas the driveline torque would move the tcase just enough to cause the shifter arm to hit the body and throw it out of gear.

In addition to all of the other stuff you're checking, don't forget to give those tcase arms a good look over and reinforce the hell out of them (or replace them with a nice tcase bucket).

[weedwacker]

check the output shaft for runout, they bent a slight amount and cause disengagement.

[MSuits]

I had the same problem with mine. Did one trail were my wife had to hold it in gear the whole time! It was the shift sheet. I put in the brass one from ZOR and never had another problem.

[MULISHA JP]

I have all the parts now. installed it in the snatch yesterday got it all buttoned up. I stuck the shifter in it to make sure everything was right and the damn thing is jammed! So I get to pull it apart for the 100th time in 2 days. Is there a trick to putting the case back together ? I'll do it once and it won't spin do it again and the shift rails are jammed. What position do the shift rails need to be in while putting the covers back on. I'll get it I'm just getting frustrated. Thanks again for everyones help! After next saturday she will be seeing some down time for modifications. I can't wait

[MULISHA JP]

Just an update. I got the snatch,HD input, and new shift sheet installed. Hasn't popped out yet. All the detent balls are now in. I now have problem with the 2wd and 4wd shift shaft, it won't move so I think it might be bent from when the front driveshaft was seized. Anyway when it was apart I stuck in the 4wd position and I hope it stays. It took a lot to get it to move. I'm taking it out saturday for a test. All I have to say is I love this thing and can't wait to start building up some more. I'll post some pics. I appreciate everyones help!