Outer Limits 4x4 Board

Can anyone help. My 92 Feroza is now stuck in 4WD (somewhere between 4L & 4H) and won't come off. Worst yet it will go in all gears but won't move forward or backward. I was pulling a vehicle and this happened afterwards. Any ideas? Do I have to take down the tranny or are there suggestions before. The lever just won't move and the 4WD dash light is also on.

Regards

KC

I rebuilt my own transfer (and took lots of pics) so we should be able to figure out what went wrong pretty quick. Could be as simple as a displaced E-clip, or even one of the check-balls has become jammed (lack of lubrication, not much 4wd use etc) - they are accessable from the outside, but first:

Do you have some circlip pliers? If so, undo the transfer gearknob, undo all the bolts holding the gearstick rubber boot/cover to the floor, rmove and it will give you access to the top of the transfer - remove the rubber dust cover and you will see a circlip holding the shifter mechanism in the transfer. Once thats removed, pull out the shifter (there will be a large spring, it will stay). 4 visible bolts removes the transfer shifter housing, there will be a rubber gasket.

After that, you will see this:



The lower shift-rod (with the spring) is for 2H>4H and will turn slightly to one side when moved - if it doesnt, the checkball is likely jammed. The upper shiftrod is for 4H>4L.

Give everything a good spray with RP7/WD40/CRC (Penetrant spray) and try to move them - don't be too heavy handed just yet.

Great Wacky. I needed to get going so I replaced the entire tranny with another spear that i had. Still the spear has a bad hum. I have seen the assembly that you're talking about but tried forcing it to move (before reading your reply) and it didn't I will try that and let you know cause this tranny is never been open before and looks in good shape. You are so right about the lubrication cause when i took it down no oil came off.Two questions though: Are the rods supposed to be able to move by hand - without the shifter, and is that part -where the rods are supposed to be lubricated (oil filled). Thanks

I really need to get it back up and running.

Why not swap the tranny case off the good one with the tranny case of the dodgy gearbox?

Well, the one that's jam I believe is by far a better (newer) gearbox that the one in use right now. On the weekend I will try the WD40 or silimar like Wacky suggested and see if it gets going. I want to get a good job done on it whilst it's down.

Appreciate the suggestion.

babyfame wrote:Well, the one that's jam I believe is by far a better (newer) gearbox that the one in use right now. On the weekend I will try the WD40 or silimar like Wacky suggested and see if it gets going. I want to get a good job done on it whilst it's down.

Appreciate the suggestion.

Like I say, why not use the good gearbox and the good tranny case?

It's a simple job to swap them over.

Since you are doing all that work change your clutch.