Outer Limits 4x4 Board

Every now and then I have difficulties selecting 4WD. I can hear a ratcheting sound (like gears not quite meshing) and then I just keep playing with the 4WD gear lever until it goes in. The lever has full travel and is noy obstructed (no body lift).

Are their any linkage adjustments for 4WD engagement?

I had the same experience with 60 series, they make a grinding sound as they go in, or you have to slowly move forward so the lever engages.

What was the solution?

Has the 60 got a body lift? A lift will interfere with the length of travel the t/case lever can go rearwards. Even if the rubber seals have been put in wrong can cause the lever to not engage fully.

Trimmed mine up with the snips and a file, no worries.

Al

Has the 60 got a body lift? A lift will interfere with the length of travel the t/case lever can go rearwards. Even if the rubber seals have been put in wrong can cause the lever to not engage fully.

No body lift.

into 4wd can sometimes need a lil rolling forward action to slot it in.. hand on the 4wd lever.. gb in 1st.. drive forward a few feet and throw the clutch in, while your still movin slot it into 4wd.. should work.. and the same techniquie but usin reverse should work to take it outa 4wd aswell..

do u use it much
if ya dont like been sed it just needs a lil rolling forward to engage
what g/box do u have
the manual select 4wd or vacuum enagage?

I have body lift and had a problem with mine not engaging but have fixed it it works fine it was actually the linkages from the shifter that had stuffed up so my mate and i pulled it all apart and repaired it and now works fine even with body lift

I'm didn't realise their was two different 4WD engagement mechanisms. I will check tonight whether it is mechanical or vacuum.
I use 4WD once every couple of months at the moment, but I will be doing some desert crossings in the future so I want to make sure everything works properly.
If it makes a difference, the build date is Jan '83. I think it's the first of the 5 speed models.

I'm didn't realise their was two different 4WD engagement mechanisms. I will check tonight whether it is mechanical or vacuum.
I use 4WD once every couple of months at the moment, but I will be doing some desert crossings in the future so I want to make sure everything works properly.
If it makes a difference, the build date is Jan '83. I think it's the first of the 5 speed models.

Is there any synchros inside the transfer case?
If so could just be the synchros not aligning properly if so, into nuetral, give it a spin and it should go in, same kinda deal as a double clutch.

I also recently had problems with my car, the clutch fluid level had dropped to much and the clutch wouldnt engage/disengage, and changing gears became a very stiff and noisy process.

If its vacum operated changer, wont it have a little button saying H4 like in a bundy, and then a leaver for low?

You are correct. I believe the gearbox/transfer case changed to the vacuum operated one as opposed to the mechanical shift in '85.' My HJ60 is 5/85 complianced and has the H4 button on the dash and a straight shift from H2-N-L4. My mates 84 model has the L shaped H2-H4-L4 shifter. He had problems selecting low 4, but as it turned out it was a slight problem in the linkages.

depends on model

the pov packs were all lever select, even the 89's (H2- H4 - N - L4)

the G etc had the vacum select (H - N - L4)

if its standard lever select you just need to roll a little bit, my old ladies doesnt like going in stationary either, just roll a bit, cant say it makes griding noises though.

Being an ex-gov vehicle, mine is the poverty pack. It has the manual select. So the question remains; Is their any adjustment in the lever or linkages?
I know I can engage 4WD by pushing on the lever, driving forwards, backwards, cluth in, out, confessing my sins to the lord o'mighty above etc.. and it finally goes in. But...
If it "just" engages, am I driving around with gears overlapping by a small percentage of the width of the tooth? Is it a dog clutch?

Surely I will be doing damage to gears if they are not engaged fully (or a dog clutch for that matter). Is this what is going on?

check your linkages is a common problem in the 60s