Outer Limits 4x4 Board

Any one know why my HJ60 pops out of 4x4 down steep hills in low range?
It's a bit hair raising when it happens! All engine & gear box mounts are good. The body is known to move and push on the 4x4 lever under extreme loads but I have removed the dust boot and checked clearence around the lever while going down hill (very hard to do on your own so I had someone else look while I drove). There is adjustment on the transfer case linkages but it looks like only for engagement from high to low range, not adjustment from 2-n-4wd. Is it a ball and detent in the gearbox which keeps the shaft in?

Got the same problem that only arose after a gearbox rebuild.
1st gear down steep hills, sometimes, but not always, pops out of gear, and doesn't seem to be caused by anything in particular.

The locating/guide brk that prevents the t/case lever from moving forward whilst in 4L is only located with two bolts. This allows the brk to pivot in turn allowing the t/case lever to move forward enough to select 2L. Quick fix is to use a lump of wood or a bar and knock the brk back into position. Best option is to add an extra tang and bolt to the brk preventing it from moving.

Sixty wrote:The locating/guide brk that prevents the t/case lever from moving forward whilst in 4L is only located with two bolts. This allows the brk to pivot in turn allowing the t/case lever to move forward enough to select 2L. Quick fix is to use a lump of wood or a bar and knock the brk back into position. Best option is to add an extra tang and bolt to the brk preventing it from moving.

What is a brk and a tang? From your description I'm guessing you a refering to the shaft going into the transfer case. How do I do the mods?
My gearbox has also been rebuilt about 5 years ago.

Brk = bracket
tang = brace, gusset....

The easiest way to see what I'm talking about is to remove the transmission tunnel cover (underneath the floor covering). The top of the t/case bracket is bolted to the top of the g/box on the drivers side. The lower part of the bracket is bolted to/through the t/case lever pivot.
To prevent the bracket from moving/pivoting add/weld a tang/gusset to the rear of the bracket allowing it to be bolted in a third spot.
A Gregory's manual might have a pic of the drivers side of the transmission.

my problem is that it comes out of gear, not out of low range or 4WD, but has only happened in 1st gear going downhill.

quick60 wrote:my problem is that it comes out of gear, not out of low range or 4WD, but has only happened in 1st gear going downhill.

Sounds like the detent spring on first gear is worn.
But check that the body isnt moving and pushing the stick out of gear. While the lever is exposed, check the urethane/neoprene bushs on the end of the g/stick itself.



Al

A heavier detent spring will remedy this for the meantime, although what you may find is the mainshaft in the transfer case which is on tapered bearings, ends up getting to much end float allowing the assembly to drop slightly, in turn the fork that runs on the dog which selects high & low puts undue pressure on the dog & disengages it when put under load [hence nuturalising]. The heavier detent spring merely helps hold it in to position, by all means don't hold me to this advice, but i did do up a transfer case out of 60series and that was about the only thing i could put it down to & was told thats what it could of been when i was making enquiries. The owner of the 60 reckons the natorious gearbox noise that they also have was near completely gone, make some enquires & see what you can find out