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Old 07-11-2012, 12:31 AM   #1 (permalink)
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Default transfer stuck in neutral

Just got back from first time towing my "new" '88 Samurai. I towed with a tow bar and both in neutral. Everything worked until I got home after traveling 2,500 miles. I can't get it to shift out of neutral in the transfer case. The tranny gears are ok. I just learned why you need to leave the trans in 2nd??? Did I burn up the bearings in the transfer case??
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Old 07-11-2012, 12:56 PM   #2 (permalink)
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Probably just a worn out shifter sheet (bushing).
Take a look here to replace it.
T-Case fix
Using the instructions, you can pop the shifter out and re-center the linkage using a large, flat bladed screwdriver.
This is a common issue with worn out t-case bushings.
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Old 07-11-2012, 02:48 PM   #3 (permalink)
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I will try that first then I assume that if it doesn't fix the problem the I need to pull the transfer case and open it up? Is it possible to freeze up the gears or bearings if I didn't have the trans in 2nd? The last day towing I put on about 600 miles with both in nuetral. Thanks Billjohn for your reply!
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Old 07-11-2012, 04:02 PM   #4 (permalink)
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You were right! The bushing is gone and I was able to move the notched shaft onto
2H. The bummer is the guys in Utah have the bushing on backorder, hopefully back in stock in a week. Thanks again!!! I'm glad God forgives too!
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Old 07-11-2012, 09:02 PM   #5 (permalink)
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That vendor has been like that for years... sorry. Here are a few places to try:

Low Range Offroad - T-case fix

Petroworks - T-case parts
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Old 07-11-2012, 09:50 PM   #6 (permalink)
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Thanks again! Just placed the order. The check engine light was also on then starts flashing. Is there anything I check or do I have to take it in?
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Old 07-11-2012, 10:19 PM   #7 (permalink)
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Here is a link to the emissions system manual: http://zukioffroad.com/Tech_Library/...ion_manual.pdf
I believe it also flashes at certain milage intervals as a service reminder. I just had to reset mine when it hit 120,000 miles.

Check engine light is covered on page 5-22 & 5-23. I've downloaded all the manuals these guys have online to my laptop and find them great for working on the Zuk.

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Old 07-12-2012, 01:39 AM   #8 (permalink)
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My just turned 100K during the tow so I didn't see that happen so I hope your right and its a service reminder. How do you reset? THANKS!!!!
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Old 07-12-2012, 08:26 AM   #9 (permalink)
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Reach under the dash to the right of the steering column.
Find a vertical brace with a two position switch on it. Just flip the switch to the opposite direction to reset.
This is what we call the $300 oil change switch.
It calls you into the dealership to get the light checked on a regular interval so they can sell you an overpriced maint. check and change your oil...
Then they just flip the switch.
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Old 07-13-2012, 10:05 AM   #10 (permalink)
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THANKS AGAIN!!!! It worked!
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