Outer Limits 4x4 Board

I just drove my ute 3hrs home from a little trip because its stuck in LOW, the 2wd/4wd selection is fine but i seem to have lost neutral and HIGH


*I can move it from L4 to H4 while in 2nd gear and nothing happens
*There is no neutral
*I undid the L4/H4 linkage and pushed the lever on the box all the way across to where it should be back in HIGH and its still stuck in low.
*The lever on the box now only has 2 points it will stop, which look to be H4 and L4 (and feels firm like it should) it should have 3 stop points H4/Neutral/L4 but both of these points give me LOW only.


I believe something has let go inside the box and its letting me move the lever all i like but doing squat.
Anyone have any ideas?
Should i undo the back section off the box and try to fix it myself?

Similar thing happened to a mates 60, was a linkage issue. When you undid the selector did the rod protruding from the transfer case retract inside at all? if so it has probably slipped off the fork it sits in and will require the case to be split.

We didn't have to remove the entire transfer case, just the rear drive shaft and took the rear half of the case apart in place. wasn't an easy job, but like most things would be alot easier second time around.

GanG wrote:Similar thing happened to a mates 60, was a linkage issue. When you undid the selector did the rod protruding from the transfer case retract inside at all? if so it has probably slipped off the fork it sits in and will require the case to be split.

We didn't have to remove the entire transfer case, just the rear drive shaft and took the rear half of the case apart in place. wasn't an easy job, but like most things would be alot easier second time around.

Yeah i thought as much, just finished nightshift, im about to go split her now, damn glad i dont have to take the whole box out!! Oh i shouldnt hav said that

Splitting the transfer in the car is not what I'd call a fun job though. I reckon when you're done you'll probably wish you just dropped the box and transfer to do it on the floor/bench.

Agree with Ray - it will be an overall easier job if you drop the box out and do it on the workbench - let us know how you get on...

Cheers

RAY185 wrote:Splitting the transfer in the car is not what I'd call a fun job though. I reckon when you're done you'll probably wish you just dropped the box and transfer to do it on the floor/bench.

A similar thing happened to mine.
I fixed it by lifting the H-L linkage on the box up and shifting. you will find there is alot of end float in the shaft that goes into the box. something must wear and the lever and fork disengage. try it before you strip box.

let us know how you go, cheers.

Chris60 wrote:A similar thing happened to mine.
I fixed it by lifting the H-L linkage on the box up and shifting. you will find there is alot of end float in the shaft that goes into the box. something must wear and the lever and fork disengage. try it before you strip box.

let us know how you go, cheers.

Oh dear, i wish you posted that 5 hrs earlier

Thats all it was just wear so i replaced the gap with a spacer, did it all back up and it works like new, i could have done it without splitting the box easily.

Lining everything back up with the box proved to be a little difficult but overall i think it was easier in car than getting the whole box out, i've done a few

Thanks for the help fella's top job once again