Outer Limits 4x4 Board

When i start going up a steep hill in 4wd the front output shaft in the transfer case gets pushed forward, this pushes the bearing forward and knocks out the oil seal and starts to leak. it pops out of 4wd and then i cant get it back in. Would anyone know why this would be?

You have probably got a broken engine/gearbox mount.

I Had the same problem with my 1989 HJ75 series cruiser. End up getting the transfer case completely overhauled and the gearbox done up.
You can get recondition kits that do both. I had Bayswater 4x4 in Melbourne do mine and they did a great job. Also replaced the clutch while they had it all part.

There opion for mine popping out of 4wd in steep climes was it was basically worn out. I had just over 400 000Km on the clock.

we pulled the transfer case apart and replaced bearings and seals and it did it straight away again,mine says only 270,000 kays on it but i don't know how true that would be.
i will get under it today and check all the mounts to see if that is the problem

Try pulling the detent spring out and give it a stretch.If you have a cab lift cut some floor out around the leaver.

hey mine does the same thing, its bloody annoying, you go to smash it up a hill then all of a sudden your revving its tits off because its popped out of hi-range, how much was it for a gearbox overhaul ?
also i can never put it back into 2wd, it takes attempt after attempt slowly crawling forward then trying to push into 2wd for it to go in.

i jacked the engine up and the passenger side engine mount has come apart,just bought a new one and about to fit it

i replaced it and took it for another drive.i got further up the hill but then the same thing has happened,the bearing has been pushed forward and it wont go into 4wd

take the boot off the transfer lever and see if it is doin the old wiggle around trick when ya go up th same hill.
See if its hitting the side of the floor and popping it out and if not it must be the box itself mate....

i pulled the transfer case apart again and found that the person who pulled it apart before me had forgotten to put a cir-clip back in front of the bearing holding in the front output shaft,will get a new one and see if that fixes the problem

scooter1985 wrote:i pulled the transfer case apart again and found that the person who pulled it apart before me had forgotten to put a cir-clip back in front of the bearing holding in the front output shaft,will get a new one and see if that fixes the problem

sounds like it could do the trick