Outer Limits 4x4 Board

Hey guys my hilux d/cab transfer case has locked up, there was no bang or crunch it did it while stationary and the truck was turned off. it is a 1983 hilux. Ive been told it could be that the stick could have jumped out of the 2 selectors i think this is how it is setup. anyways any help would be much appreciated

Benolux

The car wont drive or you just cant get the stick to move or select a range?

If you can not get the stick to move then its likely the stick has jumped out. Its a common problem with the hilux transfer and i have never been able to pin point what the exact cause is. I have usually just sourced another second hand stick and it has fixed the problem. You need to pull the concol if you have one then the gearstick boots and then pull the stick out of the top of the box and either realign it or replace it. If you realign it the chances are it will happen again.

If someone else has a definate reason as to why this happens i would love to know. Ive experianced it in at least a dozen vehicles and never been able to work out exactly what is worn out to cause it.

the car still drives ruff it is stuck in 2wd luckily and i think your right i will take it all off and try realigning it. would be good to find out the cause tho.

thanks, Benolux

BENOLUX wrote:the car still drives ruff it is stuck in 2wd luckily and i think your right i will take it all off and try realigning it. would be good to find out the cause tho.

thanks, Benolux

As long as it still drives its only going to be the stick.

ok then thanks heaps ruff yeh it still drives perfectly fine thankgod, that was my worry if it got stuck in 4wd but lucky it didnt, i will pull the boots off and the top off and realign it on the weekend and see how i go thanks for the help mate!!

Benolux

hey benno i think this is referred to as jumpn the gate and yeh its prolly your stick, at the end where it meets the selector forks, is prolly worn being an old car sic;luxs does it all the farking time easiest fix is a new shifter from wreeckers peace of piss.

ok thanks chris ill open it up and realign it for the time being and then get a new shifter thanks for that mate, got my body lift in to on the weekend so she is sitting higher now lol.

Thanks again

i have the shifter out of the transfer i got off andrew if you what it mate you can just have it

I had this problem on my old Lux.
One time I had to drive home about 30kms in low range as I had no tools to fix it
As said the end of the shifter can slide between the shift rail ends when it gets a bit worn.
I fixed mine by taking the shifter out and hitting the end with the MIG welder and grinding it square so it was a bit bigger.

LN65hilux wrote:i have the shifter out of the transfer i got off andrew if you what it mate you can just have it

I think you find it'll be different top shift have a ball on the end where as the fowards shift(the one you have) has a square end have welded mine before but proll not enough it made it better but not fixed totaly. Will get mine sorted soon as it's really givin me the shits now

Bring it back saturday morning Benno and we'll get it sorted.
Either fit a replacement stick or we'll build up the old one..

thanks guys, ln65 i might have to take your offer up on that if mine is buggered and the one you have is the same, doesnt sound it tho, and thanks jas ill pull it apart sat and see if i can fix it itll save me the trip up the coast lol. im sure it is easy, just a pain in the arse hey.

Suzuki's do this regularly as well and usually it is becaus the shifter seat is worn out.. I have not looked at a hilux one for a while but does it have a bush under the shifter ?

Sic Lux wrote:

LN65hilux wrote:i have the shifter out of the transfer i got off andrew if you what it mate you can just have it

I think you find it'll be different top shift have a ball on the end where as the fowards shift(the one you have) has a square end have welded mine before but proll not enough it made it better but not fixed totaly. Will get mine sorted soon as it's really givin me the shits now

The shifters from forward and top shift cases are the same. They may have a slightly different bend in them but they are interchangable.

Yep have had this problem before also. cept i was stuck in 2by in the sand , anyway i done the same as sic lux, pulled it out, built a weld up around it and ground it back. hasnt happened again yet but i have had trouble getting it into 4b a few times but at least it hasnt jumped out again

I have this issue and am also looking at the product linked below, would this fix the issue?

http://www.locktup4x4.com.au/product/ae ... f25c6.aspx

hey mate looks like a good idea but will you ever use 2wd lo. i fixed mine easy as thought it was rooted but i just pulled it apart and it wasnt to worn down so i filled it with thick grease and works a treat now, otherwise go to the wreckers and get one out of another lux, cheaper and easier IMO

will it fix the issue though?

if it is the same problem i had it is a common problem in a lux, if the truck didnt make a clunck and it stopped working randomly then it should be easily fixed. unscrew the rubber boot then unscrew the top off the transfer shifter and you should find selectors. the stick will look worn and i think yours will have a ball on the end maybe or it could be square ended, either if the stick looks worn then try building it up with grease if this fails then weld it up then grind and then if you get desperate go to the wreckers and see if you can get another one. i assume the twin shifter would fix it as long as the selectors havent worn down and aslong as they are the correct shifter for you transfer, dont forget if you get the twin selector you need to remove the pin in the transfer so the selectors can move independantly.
hope this helps mate
Benolux