04-13-2007, 07:00 PM
Join Date: Sep 2005
Location: Western Australia
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.