Topic: TransferCase popping out of gear???

[sam24462]

I need help!

Background: 1985 Toyota 4Runner.

I purchased a single 4.7 transfer case from Marlin about 2 years ago and ran that for about a year with no problems. Then I decided I wanted the second gearbox. So I bought a Marlin adapter and found a donor T-case to get the box from. I installed everything per the setup instructions and it seemed to go together fine.

Problem: Everything works good except the Front Box pops out of gear. It only happens when the rear case is in 2wd/hi and the front box is in Low. It also only happens when I am driving down hill so there is no engine load. I am on my third and hopefully final attempt at fixing this problem. 

I do have the heavy duty detent ball springs in all three shift rails.

Note: I noticed that the instructions said to trim the driver side shift rail so it does not protrude out of the front of the rear case. I think that Marlin may have done this originally on the rear case because it does not protrude at all. See pics below;


Rear Case 2wd/Hi








Rear Case 4wd/Hi



Rear Case 4wd/neutral



Rear Case 4wd/Lo






I know that the shifter is not hitting on anything because I have tried driving with all covers off and it does not hit anything.

Other possible problems I have heard:
Worn gears
Worn shift fork


I included some pics of the gears, I don't see any issues with them, but maybe your eyes will notice something wrong and be able to help diagnose the problem.













I know this has been asked several times but I haven't really found the answer yet. I am at a loss on this problem

[sam24462 [OP]]

:Crickets: 

[Bazzi]

I dunno. I am kinda just replying to subscribe

But I would try and look at how the shifter moves. how easy is it to shift and so on. I also wounder if there is any leanght difference in the shifters mabe the fork is sitting loose on the gears or something... I am just shooting in the dark tho

[sam24462 [OP]]

I dunno. I am kinda just replying to subscribe

But I would try and look at how the shifter moves. how easy is it to shift and so on. I also wounder if there is any leanght difference in the shifters mabe the fork is sitting loose on the gears or something... I am just shooting in the dark tho

The shifter wouldn't matter as long as its not hitting anything such as sheet metal. The Case shifts smooth but I have the heavy detent ball springs in so I have to give it a little bump to shift.

I guess if the shift fork was worn, the clutch sleeve would have some play in it.

Can anyone get me a measurement on the shift fork.

Shift fork No. 2 from the reduction gear case. I don't have anything to compare it to.

[Bazzi]

nah... I am guessing your shifter drops out completly. if the fork would drop out from the gear you would have to disasembly the whole thing to fix... am I getting this right

[sam24462 [OP]]

nah... I am guessing your shifter drops out completly. if the fork would drop out from the gear you would have to disasembly the whole thing to fix... am I getting this right

Everything works fine. It just pops out of gear and I have to stop and put it back in gear. The front case just slips out of low.

[Bazzi]

do you have a photo of the t-case shifter... installed

[sam24462 [OP]]

If anything the boot is tighter in the hi gear.

[Bazzi]

I would be looking at the boot... watch how the shifter moves when you are coasting. Also watch the other shifters they might give you a clue to what happens. = might be the problem that all the shifters move but there is a litle less free play for that one. might be resolved by some slight bending of the shifter. I had a simular problem that was resolved with bending the shifter and adjusting the shifter boot.

[emsvitil]

Take the boot off, and see what happens........

[sam24462 [OP]]

I am going to change the gears because I have an extra set and it is already taken apart. Then I will install it and try with no boots. I will keep this updated.

[sam24462 [OP]]

I have a sneaking suspicion that I found the problem

I decided to change the gears that had a little wear on them and opened a can of worms. The bearing that slides over the "coupler" (not sure if that is the correct term) inside the gear is toast. I am amazed that I wasn't having more issues. The bearings were actually welding themselves to the race

The gear was wallowed out about a sixteenth of an inch. I don't think it damaged anything else so maybe I got lucky.

[zippo]

I think its awesome you have a stove in your shop, or a broken TC in your kitchen. NICE!

[sam24462 [OP]]

I think its awesome you have a stove in your shop, or a broken TC in your kitchen. NICE!

The garage used to be an apartment and I havn't finished converting yet.