Outer Limits 4x4 Board

A mate has a 89 model hilux, 2.4 diesel 5 speed, the transfercase seems to be jamed in 2H, cant select 4h or 4l, lever will not move but was good as gold a couple of weeks ago. Has anyone got any ideas what the problem could be and the easiest way to fix it.
Thankyou.

A couple of quick things you could try.

Remove the 4x4 light switch off the side of the transfer case, it may be sticking. (Unlikely)

Remove the allen key grub screws that are on either side of the case. Behind the screw is a small long spring, at the other end of the spring is a small ball. These help hold it in gear and the ball may be sticking or something. (Unlikely)

Do these one at a time and then try to move it.

If those haven't worked remove the shifter and see if you can move the forks in the case using a big arse screw driver. The fork on the right is 2wd/4wd, the fork on the left is high N low. If you can move them then its in the shifter itself. If not then its in the case.

Other then them thins it'd be a remove the whole case and pull it apart to look.

cant they do a thing known as jumping the gate? its happended to mine and m8s b4 a few times, ya just undo the cover plate on the inside of ya cab and remove the boot from around the sticks, once this is off undo the 4 bolts going into the case to get that plate off so you can see inside the case then wobble the stick till it free's up? i no its hard to understand but does anyone no how to put this in simple??

the lever will have jumped out of its gate, pull the boots off to expose top of the box, roll back the boot on the transfer lever, remove the sirclip take the lever out and realign, mime did this on the weekend and only took 5 mins to fix.

ShAgGS wrote: remove the sirclip .

mines done it a few times now i just undo the 4 12mm bolts till i can lift it up and put the stick near where it would be in 2H and it finds it's home do the bolts back up and the rest is stated above. Like to know where yours has the circlip

roll the little boot at the bottom the the stick out of the way and there it is, clip,retaning washer and spring hide below.

So you undo that instead of the 4 12mm bolts

yep, heaps easier.

Thanks heaps guys, done what you said and was fixed in 5 minutes.