Transfer Box jumps out of 4WD

[Gwatty]

Hello

I'm a new here, please be kind

My GV6 2.5 has always jumped out of 4h back to 2h, some time this causes the transfer box shifter to jam up completely. Fortunately I've found out how to free it, but that's the effect not the cause.

From my research I've found a few suspect causes. "Wind up" due to dry roads. Worn transfer box mounts, a pneumatic problem, a front Dif problem and finally a gear in the transfer box that Suzuki Modified to stop this from happening.

Has anyone managed to cure this problem, if so how (and more importantly, how much ). Can any of the above be ruled out.

Finally can anyone recommend a good independent mechanic in the Bristol (UK) area who specialises in Suzuki.

Thanks in advance

[Bex]

I don't know if the transfer case in your car is similar to the 1.6L transfer cases, however, similar issues here:
http://www.suzuki-forums.com/suzuki-...s-out-2wd.html
Have you checked the tranny case fluid (or ever replaced it)? If this is not the issue, it may very well be the shift linkage. Does the shifter pop out, or does it stay in place and yet the car goes into 2wd?
Personally, I don't know anyone in your area. We do have a poster, Rhino, who is in the UK. You may wish to send him a PM or email, to see if he can recommend anyone.

[xxx]

wrong forum, !
and what year?
99 the whole deal was redesigned.

box shifter to jam up completely

the tranny , crossmember mount is BAD>

do not use 4wd on dry pavement, not even wet .
use it only on sand ,dirt, grass, mud, ice snow , clay, and the like
if you dont RTM you will destroy the transfer case like this Jeeper did;

RTM;

http://kickfix.ac-vw.com/part-time-test.html

warning , when I say, 4wd, that means its 100% fully engaged and fully 100% active with the hubs locked.
this car has no center differential.

[fordem]

Searching the internet for possible causes is fine, but having found that information, you then need to see which if any apply to your scenario - that's something we cannot do for you, and what's applicable to my vehicle, won't necessarily apply to yours...

Let's work through them one by one ...

First - the front diff problem does not cause the transfer case to jump out of 4H, back to 2H, so let's rule that one out - all it does is create one heck of a bang, which may eventually break something, so it should be avoided - it will eventually lead to the front differential freewheel assembly slipping rather than applying power through the front wheels.

Let's look at wind up from dry roads next - I'd say that's unlikey to cause the transfer case to jump out of 4H, what it does is cause the front diff to go bang - you also should know whether you are driving the vehicle in 4WD on a dry surface, making this an easy one to rule out.

Worn transfer box mounts - this one is new to me, but, theoretically possible - although in my opinion unlikely, since the box would need to move fore & aft to bounce the lever back to 2H, rather than side~side, which is more likely with worn transfer case mounts - body lifts are likely to aggravate this if you have one. Watch the transfer case lever as you apply power - is there a signficant amount of movement?

Gear problems - I believe there's a bulletin on this specifying the years it's applicable to - unfortunately you haven't told us what year vehicle you have, so it may or may not apply.

[xxx]

great predictions, under chaos.!
and hands on is best and any mods to car, jackups etc.

[Gwatty]

Hi Everyone, back from work now so I can fill in the rest of the details. It is a 1999/2000 (Uk T Reg, the Reg used to change in August).

Sorry about posting in the wrong forum, got down to Vitara in the list and got over excited! If any mods want to move me along please feel free

An easy fix is to get the fluid changed, won't do any harm, needs doing sooner or later and is cheep! Thanks Bex

XXX Thanks for the advice no more driving in 4WD on the road, however bad my transfer box is I don't want it in two bits! The Shifter gets jammed if the leaver is on the wrong side of the gate when it jumps from 4h to 2h.

Fordem, thanks for your answer, just needed to bounce the possibilities off of someone.

There is a bang/thud when it jumps out of 4h. The 4WD light goes off but the leaver only moves back about about a third of the way to 2h although the car will still drive.

There is little or no movement in the transfer box leaver when you accelerate for as long as it lasts in 4WD, usually about 10-15 seconds before I'm back in 2WD. In 2WD it looks solid enough.

Thanks again everyone

PS No mods, everything is factory standard

[fordem]

Under what circumstances does it jump out of 4H? What sort of terrain are you driving in? Is it consistently jumping out of 4H after 10~15 seconds of operation?

I don't have the TSB handy but I believe your year of manufacture falls into the period with the transfer case gear that was redesigned - which is what yours is sounding like.

[Gwatty]

Hi Fordem

It won't stay in 4WD under and circumstances. From standing start you'd be lucky to get into second. Any surface it, there is just a clunk and you are back in 4WD.

Thanks

[fordem]

You have a transfer case issue - and not necessarily the one covered in the bulletin.

[Gwatty]

Okay, Thanks for your help Fordem