Outer Limits 4x4 Board

just finshed rebuilding the tcase however 4LOW and neutral i can not selectct. the 4wd light comes on when i go into 4low but it just doesnt click and lock it in. it will just sit there and can be easy knocked out.
that was my main problem untill i got a bit carryed away and took it a bit harder on the stright runs was all going good untill i herd this horable grinding noise from the tcase at about 60kmh so i hit the clutch and it went away. i pulled over and then took off real slow in 1st it was all ok then i went into 2nded and that same noise again. i have got no idere what it could be but i think it does it when it got load on it/bit of speed.

this was a real letdown for me i though i did everything right. i will add though i wasnt sure whitch was the shift collar goes on.

so any ider why my tcase sounded like it was about to blow up and why i cant click into 4low?

i used this a guide i may or may not have done it 100% to that
http://www.trail-gear.com/tech/zuk65gears/index.html

thanks

i just thinking could it be sumthing simply like the shifting coulars are on backwards or anything?

if it knocks out/falls out real easy are you sure the little ball for the detent for the lever is in??without it it wont lock in gear and could just fall out??as for the grinding noise,did you put gears in it??if so did you grind the case enough?

sorry if this does not help,matt

no i just rebuild the case didnt add new gears. i think i put the little ball in right i did it to what the instructions said.
but how many balls are there? because i only remeber putting in a small one for a shifter and a bigger one for the 4wd light.

i put the smaller ball in here as shown http://www.trail-gear.com/tech/zuk65gea ... 44-600.jpg


but looking at this pic http://www.trail-gear.com/tech/zuk65gea ... 50-600.jpg

i dont think i put in that ball as i didnt have one

all i did was put in the spring and cap

ive got the tcase apart now and everything looks like its on the right way. as you would expect after a bit crunch there are metal shaving everywhere.

i think it is somthing to do with the shifting?

i will add that i also have the 2wed lowrange but not twinsticks

ok sorted it all out all should work alright but 1 thing. there is movement in the ouputs it moves about 3-4mm longways (diff to diff)

here is a pic showing it out at it max. this pic was taken of the output at shifter side. it has always had movement on the front output as far i remeber.
i have got the case backtogether but now the movment is in the rear output?

sounds like you left the roll pin out of the shift fork.

3-4 mm that aint right! did you shim the case? it should have 0.020" -0.030" from memory. thats about half a mm

i didnt shim it onyl what shim where in it. just 2 of them. i know 3mm is ALOT of movement. i am thinking there maybe 0.5-1mm of play in the output bearings causing it to move. but what is strange is the movement is only on the rear output?

ok took it for a test drive well not realy got 10m down the street and bang it poped out of 2wd HIGH into 2wd LOW i am guessing it because of the play?

Rip it out, take it to someone who knows what they are doing.

GRPABT1 wrote:Rip it out, take it to someone who knows what they are doing.

that the plan if it needs to be simed

but being modified for the 2wd low will they get confused?


if it doesnt need to be simed and it coul be somthing simple i wl do it myself