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Discussion Starter · #1 ·
Hey Everyone,

I'm actually posting this for a friend so here it goes.

Its a '87 FJ60, OME 2.5" Lift, 32" Tires, and the I6 (2F?) has been built up...alot <IMG SRC="smilies/biggrin.gif" border="0">

Anyway, whenever he pops it into low it sits there for a while and then when a good amount of torque hits it, it pops out!

Its cause some pretty lame situations on the trail, and we tries adj the linkage but it didn't help!

Any ideas?

Thanks!
-Justin
 

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Try taking the boot off and making sure that the shifter is geeting all the way seated back in to position. After my OME install mine also poped out of 4low and it did it beacuse the shifter was running into the floor so makig it feel like it was fully engaged, but it wasn't. <IMG SRC="smilies/beer.gif" border="0"> <IMG SRC="smilies/blender.gif" border="0">
 

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if the linkage is adjusted right then it would have to be an internal problem in the t-case. i'd say maybe a bad shift fork (worn pads) or a bad synchro sleeve, possibly the synchro assy itself. either way, the only way to know for sure would be to tear down the t-case, at least part of it so you can get a look at the front output shaft and 4wd synchro assy.
i would definetly doublecheck the linkage first!
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Check your motor mounts; when they are broken the engine can move and it knocks the linkage out of gear. If it is not the linkage, chances are that bushing/bearing on the Lo gear output shaft is worn (It wears continuously in Hi) allowing the gear to cock on the output shaft and pop the clutch gear slider out of engagement with the dog teeth on the Lo output gear.
 

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On high milage transfer cases, the high range gear gets worn and causes the transfer case to pop out of gear in Low range. I know it sounds backwards, but it is VERY common.

You can rebuild for $150 labor and $300 in parts or you can try to locate a used transfer case.

I would opt for the latter seeing you can find them pretty cheap.

The quickest fix is to use a bungee cord to keep it over to the right <IMG SRC="smilies/biggrin.gif" border="0">
 

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i agree with cafj60. take the boot all the way off and wheel it to make sure the stick is not contacting the body. this has been discussed on this board before and there have been several instances where the shifter was contacting the body.
 

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Discussion Starter · #7 ·
I'll check the motor mounts, I'm starting to think its internal. We already checked the boot and it was ok.

Apparently its been doing this for a while (pre mods) so its probably time for a new T Case.

Thanks for the help

-Justin
 
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