Transfer Case slipping out of 4HI...

[Swede]

Has anyone come across the problem of having their Transfer Case popping or slipping out of 4HI back into 2HI?

At first I thought it may be pressure from my shifter boots being stretched out due to my BL but I still have the issue after relocating the boots further down the levers to the stock position so that can't be the cause. Is there a spring in there that gets weak by any chance? Thanks.

[Robinhood4x4]

It's a common problem with body lifts. You might have to clearance some sheet metal around the shifter.

[Swede]

It's not that. I've checked. There's at least 3/4" at the closest point between the lever and the body. It has to be something else, possibly internal?

[Cheese]

When people have odd problems like this, I ask what was changed?

It is pretty unlikely that something suddenly quit working.

It is pretty likely that something was changed and that change is causing the problem.

Recent bodylift install? Suddenly something that is moved in the cab but is actually between the frame rails does not like to stay moved as much?

My front case had issues like this because of crappy boot location/binding after a drivetrain swap. It would shift fine, it would just pop out some times.

So, I fixed the boot and have no more issues.

[4runnerchevy]

It's not that. I've checked. There's at least 3/4" at the closest point between the lever and the body. It has to be something else, possibly internal?


3/4" is not enough, the tcase has been known to move alot more than that. Also check the mount that the tcase sits on. I also had this problem early on, and had to clearance the body.

[Robinhood4x4]

Things move around when you're driving. When you give it gas, the transmission torques over and hits your body.

[4runnerchevy]

Scary thing when your climbing a steep hill in low, and bam your suddenly in Nuetral.

[MTL_4runner]

Things move around when you're driving. When you give it gas, the transmission torques over and hits your body.


X2

If you can reproduce the problem fairly easily, then drive around with the boot off for a little bit and see how much the X-fer case is torquing/moving under load. As the body gets higher, the more likely contact with the shifter.

[Cheese]

In double (triple?) low, my shifters can come all the way up and over to poke my leg, a good 2 inches and this is with a FROR crossmember.

I had my case pop out dropping into Hell's Gate. I think the seat is still streaked.

[4runnerchevy]

Scary thing when your climbing a steep hill in low, and bam your suddenly in Nuetral.


Correction:

I didn't read enough, I have never had this problem in high range. Only in low is my shifter close to the body. Possible rail, or fork failure ?

[drguitarum2005]

why does everyone always assume (and speculate at) the worst case scenario when its usually something simple? quit looking at failures of internal components (shift rails, forks, gears) and check the obvious first which is the clearance issues from a body lift. if you had internal problems with the t-case im sure you'd be seeing more than the occasional "popping out of gear"

[Swede]

I did drive around with the shifter boots off but I couldn't get the lever to contact the body at all, mind you it did come close a few times like maybe 1/4" or so. Usually when it does pop out though, I'll be running down the road at highway speeds where there is less torque involved to move the T/C around, but where there is a fair bit of vibration instead. Maybe I will trim the body anyways just to eliminate that possible cause and go from there.

[Whitey]

why does everyone always assume (and speculate at) the worst case scenario when its usually something simple?

Easy with the generalities.


I did drive around with the shifter boots off but I couldn't get the lever to contact the body at all, mind you it did come close a few times like maybe 1/4" or so. Usually when it does pop out though, I'll be running down the road at highway speeds

How fast are you going in 4wd???
I was under the impression that a 3" body lift was too much for this truck.

[BruceTS]

With a 3" body lift you can easily get 2+ inches of body to frame deflection. Hit a bump in the road and it will pop out of 4WD. 3/4" is not enough clearance.....