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My FJ60 1983/85 has had a little problem on the weekend just gone. I was putting the front wheel up on a termite mound to grab a cool pic when a helluva lot of grinding noise came from the gearbox. I found that by pulling the 4wd leaver down while accelerating prompted it to click (or what seemed to be) back into gear.
I think this sounds expensive, but am not too sure. The engine is a 2F with around 250k on the speedo.
To make matters worse when I finally got the wheel on the mound and was posing (squatting under the car just behind the front wheel) we found that the camer was broken. So Dumdunce, do you know how to service a Kodak 4200 digi cam?
Cheers all
SANGA
[quote="MissForbyNooB"] I've played with you AND your missus. [/quote]
Yeah I gots a body lift, but I did the right thing and pulled out my 4wd lever and bent it into a better position for gear transfer. I don't think it is hitting the side of the opening at all, at least it wasn't when we changed the shape at Chrissie
[quote="MissForbyNooB"] I've played with you AND your missus. [/quote]
The high-low range engagement clutch may be slipping. Check that the fork detent spring isn't loose (17 mm plug on top of the transfer) or has lost its tension. If this is OK, the main output shaft may be worn to allow the clutch to slip and needs to be replaced.
it will be either was Carts or beanz has suggested; or sometimes if you have a lot of bearing slop in the transfer output it can cause enough misalignment between the hi/low fork and the case to pop it out under load.
I'd start by jamming it in low range, disconnecting the transfer lever, then taking it for a drive and trying to duplicate the situation, to eliminate the possibility of the lever hitting the body.
also can you clarify - is it a vacuum 2/4 transfer or manual lever, and if manual lever, are you pulling the lever BACK or RIGHT to pop it back into gear? if BACK then it is the 2/4 clutch that has the problem, and this is far more common - it requires a transfer overhaul but should not need expensive parts (eg output shaft and clutch). if RIGHT then it is the H/L clutch, and that's probably bad.
Cheers, I believe it is manaul transfer and to my knowledge I am only pulling down but may need to remove boot to see if I am in fact pulling right as well.
Will give it a burl this weekend to confirm
Thanks heaps
SANGA
[quote="MissForbyNooB"] I've played with you AND your missus. [/quote]
when a helluva lot of grinding noise came from the gearbox. I found that by pulling the 4wd leaver down while accelerating prompted it to click (or what seemed to be) back into gear. 
