Problem with Transfer Case

alternator · 11-03-2009, 12:45 AM

Yesterday I was driving my Samurai very gently on the streets (no off-roading), and just as I was driving I heard a click in the transfer case, and all the sudden power stopped being transferred to the rear wheels. The shaft between the gear box and the TC is turning, but the TC is not transferring anything to the wheels. I tried to move the TC stick, but it seemed to be jammed. I have recently upgraded the TC to Tough Gear 6.5:1 gears, and I used it while off-roading a couple of weeks ago without any problems, but suddenly this happens while driving on a street. What could be the problem? I took the car to a workshop to inspect the TC, but I'm very disappointed, I certainly don't want to go back to stock TC, after experiencing the might of 6.5:1.

Billjohn · 11-03-2009, 09:33 AM

Did you replace the shifter bushing (Suzuki calls it the 'shifter sheet) when you rebuilt? If not, the shifter just jammed. Common problem with an old bushing.

You can do this while the t-case is in the vehicle.
Pull the shifter.
Use a long handled flat tip screw driver to reposition the shifter rods inside so that the notches line up.
Replace the shifter.
Done.
This article has pix...
Tcase Fix

alternator · 11-03-2009, 01:28 PM

Quote:

Originally Posted by Billjohn

Did you replace the shifter bushing (Suzuki calls it the 'shifter sheet) when you rebuilt? If not, the shifter just jammed. Common problem with an old bushing.

You can do this while the t-case is in the vehicle.
Pull the shifter.
Use a long handled flat tip screw driver to reposition the shifter rods inside so that the notches line up.
Replace the shifter.
Done.
This article has pix...
Tcase Fix

No I didn't replace the bushings. Should they have been replaced? I don't know if the shop cheated me, but they completely removed the T/C, drained the oil and opened one of the plates. They said the problem was from that little bearing ball inside, which they replaced. Car is out now, but the shifter is wobling a lot more now than it did earlier. I think I'm going to place an order for that poly bushing in lowrangeoffroad.com.

ack · 11-03-2009, 07:55 PM

Quote:

Originally Posted by alternator

...I think I'm going to place an order for that poly bushing in lowrangeoffroad.com.

I would heartily recommende that you buy the Zuks OffRoad (ZOR) Brass t-case bushing.

ZOR Zuks Off Road

Scroll halfway down the page for a description.

inexpensive and rugged.

Oh and they work! I have one on my DD:

Baratacus · 11-04-2009, 12:45 PM

I strongly suggest doing anything that Ack heartily suggests doing.

ack · 11-04-2009, 03:32 PM

Quote:

Originally Posted by Baratacus

I strongly suggest doing anything that Ack heartily suggests doing.

Wait, now - let's not become lemming-like!

Even I find myself FOS occasionally and end up tagging myself out for it.

I'll try not to use the phrase "heartily suggest" in future posts.

...but I DO think that the ZOR T-Bra is a great product!

Thanks for the compliment though, Baratacus.

Baratacus · 11-04-2009, 10:07 PM

I'm just sayin, you don't throw around hearty suggestions that often, but when you do it's generally pretty good advice...

Billjohn · 11-04-2009, 10:30 PM

Alternator...
If you haven't ordered it yet, PM me your address. I have an extra one here at the house.

alternator · 11-04-2009, 11:07 PM

Quote:

Originally Posted by Billjohn

Alternator...
If you haven't ordered it yet, PM me your address. I have an extra one here at the house.

Wow that's great! I have already placed an order with Rocky Road, but they still haven't fufilled it for me, so I'll just cancel it. Do you have both the bushing and the sheet? Cuz I ordered both items.

Billjohn · 11-04-2009, 11:29 PM

The shifter sheet for the transfer case is what I have. It is the bronze version that ZOR makes. It will NOT wear out... Myron makes some quality stuff.
You will be pleased.