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Old 04-11-2007, 08:49 AM   #1 (permalink)
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Question SAMURAI Transfer case

Hi to all I bough a SAMURAI last week for restore (real cheap $250.00) is a 1987 and it has being standing with out work for like 3 years ,and I has being doing some work on it ,and the engine and the transmition looks fine but the transfer case is not transferring the power to the rear or front axe ,and is on N position and I an unable to move the stick to any position like H 4wd or L 4WD or H 2wd , can you tell me if this is common problem and the procedure to fix the problem .
Thanks
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Old 04-12-2007, 01:42 AM   #2 (permalink)
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try reversing in 4H for about 10m then stop the car and try put it back in then.

Iv had the same problem and this seems to fix it all the time
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Old 04-12-2007, 08:09 AM   #3 (permalink)
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I can't move the shifter. It is stuck in neutral. Any suggestions?
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Old 04-13-2007, 07:00 PM   #4 (permalink)
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Default Transfer case problem

Don't worry this is an easy fix. What's happened is the bush which keeps the transfer case gear lever in position has disintegrated and allowed the gear lever to drop leaving the transfer case stuck in neutral. You can fix this from inside the cab, no need to remove the T case or even get under the vehicle. Don't know how much a new bush will cost you but here in Australia it's between 15 and 20 dollars depending on where you buy it. The way to replace the bush is:

1 Remove T case gear knob.
2 Remove the screws holding the T case gear lever boot and remove the boot.
3 Remove the smaller boot from the top of the T case where the lever attaches to the T case.
4 Push down and turn the lock ring holding the gear lever in position, it's a bayonet fitting.
5 Lift the gear lever out.
6 Install the new bush in its seat, you'll be able to see where it goes.
7 Installation of the gear lever is the reverse of removing it.

This shouldn't take more then an hour all up. If there are any remnants of the old bush in the seat make sure you remove them otherwise you won't be able to push the lock ring down far enough to lock it.

I had the same problem with my T case about ten years ago after crossing a big river in Nth QLD. No matter what I did I couldn't get it in gear. I ended up removing the gear lever and changing into 4H by shifting the selectors with a screwdriver. Crude but it did the job.

Hope this helps you out.

Cheers
Footloose
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Old 04-14-2007, 04:54 PM   #5 (permalink)
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Thanks a lot for your help I already order the bushing and I think that I will get it by Monday and cost me like $13.00 USD so not a big thing ,as soon as I get al do all the procedure that you describe and I let you guys know if this is the solution
Thanks a lot
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Old 04-21-2007, 04:40 PM   #6 (permalink)
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Hi to all
Thanks footloose I already fix the problem ,as you describe the neoprene bushing was the solution I did all the procedure that you describe and the car is working
Thanks again to all for your help this forum I better that the best repair manual than you can get

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Old 04-21-2007, 10:33 PM   #7 (permalink)
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G'day Virgopelo,

Glad to read that you've got your Suzi going again. Glad that I was able to help you. How long did it take you to put the new bush in? You shouldn't have any problems like this in the future as the new bush is made of a different material to what the original one was. If by chance you do, you know how to fix it.

Cheers
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Old 04-26-2007, 07:59 AM   #8 (permalink)
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Hi footloose to fix the problem I spend like 30 minutes because I had some difficulties screwing the metal lock ring cover but everything was real easy especially because since I an doing a general rebuilt at the car ,it was with out the carpet and the gear boot ,but the compartment it was completely full of water and mug , by the way do you know if you need to add oil the part where the shifter go or if it will be lubricated from the oil from the transfer I donít add any other lubricant
Thanks again for your help .

Cheers
Virgopelo
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Old 04-30-2007, 06:32 AM   #9 (permalink)
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G'day Virgopelo,

The gear shifter is lubricated by the oil in the transfer case, no need to add any extra oil unless you drained the transfer case. Good to read that you fixed your problem in 30 mins.

Cheers
Footloose
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Old 12-07-2007, 01:27 AM   #10 (permalink)
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Thought I would have to replace the transfer case ......... FOOTLOOSE .... Thanx YOU ROCK!!!
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