Outer Limits 4x4 Board

Hey all,

I have a Jimny (3 inch B/L) with a Sierra transfer and stage 3 rock hoppers. The problem is the when in low the transfer case jumps out of gear back into neutral. You can even here is happening when my passenger is holding it in gear.

It seems to happen more when I rev up to 4000, the floor is cut and there is rubber there but I don't think this is causing the problem. I replaced the oil as it was bad anyway to Synthetic 75-90w and didn't make a difference.

Any ideas would be appreciated thanks,

Harley

Hi mate,

Not sure but would get with S3 with larger tyres? you will be stressing the standard transfer mounts pretty badly. They are probably flexing and popping it out of gear? Internals of the case is out of my league am sorry. Good luck sorting it out.

Cheers

Take the boot off and check tcase shifter clearences under drive conditions.
You may have a tearing tcase mounting rubbers and its not obvious.

Mine poped out from L4 only, cause my tcase mounts were trashed and the shifter was contacting the floorpan.

Also check your engine mounts too.

If it's jumping out check your transfer sheet, the nylon washer/bush under the shifter, this is quite common.

I also bent my passenger side transfer mount that knocked the case and prevented me getting low range, but as you have cut out the floor this shouldn't be the problem

I know this sounds silly, but the boot seems to be stuck to the floor. How do I get it off!!!

Sierras have 4 screws, one in each corner. The boot is sanwiched between the floor and a metal plate.

Jimnys I guess may have somthing similar.

i'll come over and help you out this week after i've dumped the starter back in mine if you want. did the previous owner beef up the transfer mounts? Cos i know you give it a hard time!

Hey i have a sj80 with hilux diffs and series 3 rock hoppers with 35s and mine is popping out of low 4 aswell would like to see how to fix the prob i think mine could be internal but is dangerous when hill climbing also seems to pop out in reverse on a hill but over 4000rpm going up goes oout aswell

Just check as well that the tcase stick isn’t hard up against the floor. Because as the case torques it will knock it out of gear. This happens on a zuk where you have a bodylift.