Outer Limits 4x4 Board

I have a hilux Ln106 and have been getting troubles in 4wd.
When going down a hill and she is in low 1st using the engine for braking, it will randomly pop out of gear and into neutral.
It is the transfer case because i stopped, pushed the stubby lever back into 4 low and it drove again.
It has happened a number of times since then.
I put in a recon gearbox about a year ago and it was sweet. Just the transfer has been getting progressively worse and its a bastard to get in and out of 4wd. The lever sometimes needs a stupid amount of force and rolling the car back and forth etc.
I have a recon transfer to put in i just really don't want to pull out the entire gearbox again.

If anyone could shed some light to a simple fix that doesn't involve dropping the entire box or let me know what i did wrong i would greatly appriciate it.

Andrew.

U can split the transfer off the back of the gearbox. So no need to pull the whole gearbox out.
The transfer may have too much end float in the gear set up making it pop out of gear?

Matt

Cheers for the reply Matt.
What exactly is end float and how can i rectify it?

Andrew.

Just about have the transfer out, just have to get those bloody forks right.
I forgot about a bog hole a while back and the oil in the box looked like cream.
Seems to be a lot of shit on the forks too. Maybe preventing smooth shifting?
Should have the new transfer in tomorrow and i'll try suss the current one out. Anyone know where to get a top shift conversion for duals?

Andrew.

End float will allow the gears to move back and forth. The box will need an overhaul to rectify that, but this is only a guess.
May just be a shifter problem, it's hard to say without looking.
There is a write up on how to conert a forward shift to a top shift. You will need to strip the case and swap the shifter rails from memory.
Good luck with the transfer change over, not to bad with a few beers

Cheers
Matt

So farking close!
Can't get the forks to let go.
I have the stick in 4 low and it just holds on.
I really don't want to drop the whole box as those bolts on the bell housing against the firewall are a bloody nightmare.
Any suggestions?

Check the bible for the workshop manual.
What do you mean by stuck forks?

Matt

AHF01U wrote:So farking close!
Can't get the forks to let go.
I have the stick in 4 low and it just holds on.
I really don't want to drop the whole box as those bolts on the bell housing against the firewall are a bloody nightmare.
Any suggestions?

take the 4wd shifter off the top of the gearbox (can do this from inside the car)

Went through the manual and it says to drop it out (transfer and gearbox) as a unit.
Had to call it a night after a cracker egg on my forehead, stripping the head off a bolt and a serious lack of beer.
I was thinking i should have removed the gear lever but i was just over it by then.
I will continue the process of swearing and hurting myself next weekend. Don't know why i keep working on the bloody thing, i need to sell it and buy a single cab.

Heaps easier to drop the transfer off the back of the box then taking out the whole lot.
Just make sure you pull the 4wd stick out as dillza said, as the shift forks on a forward shift case go into the next housing.
Support the gearbox when you drop the crossmember out.
And always have beer on hand This also helps when you hit your head.

Matt

Could just be a detent spring broken see steps 24,110,111 for them http://www.trail-gear.com/pdf/470kit.pdf" onclick="window.open(this.href);return false; But if you have a case i'd just swap it over