Transfer Case problem

37
45
18
Location
Iran
Hello everyone

I had rebuild my Deuce's transfer case in last rew months . No problems until yesterday I was taking it to shop for taking out stuck screws of windshield , I had noticed high range didn't engage. When I was trying to hold the lever by hand , the only thing that happened was grinding sound and when released the lever , stayed in natural.
Low range engages with no problem.
It sounds like the fork is going out of its place to front of the synchronizer and when the lever pulled to engage high range, the fork reaches its limit and contanct with transfer case body and no way to back and engage high range.
I have no idea to whats going on in my Deuce.
I'm waiting for your helpful replys.

I'm sorry if my english was wrong somewere.

Thanks
 

Mullaney

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Charlotte NC
Hello everyone

I had rebuild my Deuce's transfer case in last rew months . No problems until yesterday I was taking it to shop for taking out stuck screws of windshield , I had noticed high range didn't engage. When I was trying to hold the lever by hand , the only thing that happened was grinding sound and when released the lever , stayed in natural.
Low range engages with no problem.
It sounds like the fork is going out of its place to front of the synchronizer and when the lever pulled to engage high range, the fork reaches its limit and contanct with transfer case body and no way to back and engage high range.
I have no idea to whats going on in my Deuce.
I'm waiting for your helpful replys.

I'm sorry if my english was wrong somewere.

Thanks
.
I can't help but wonder if the linkage has anything to do with the problem. I have a completely different truck - and Low range would work just fine. Hi range wouldn't work until I adjusted and lubricated that linkage. Might be that a good shot of WD40 might solve the problem...
 

gringeltaube

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In the best case, the TC mounts are loose and the whole TC has shifted to the rear of vehicle, not allowing full (inward)travel of the shift shaft when shifting into high gear.

Second best scenario (and also relatively easy to check and fix): somehow the fork's set screw (#12) broke loose and the shift shaft is moving inside the fork. Make sure the screw is firmly tightened and safety-wired.
1633955454099.png DSCI00004 B.jpg

If nothing obvious, the whole T-case has to come out and be opened, to inspect the synchronizer.
 
37
45
18
Location
Iran
.
I can't help but wonder if the linkage has anything to do with the problem. I have a completely different truck - and Low range would work just fine. Hi range wouldn't work until I adjusted and lubricated that linkage. Might be that a good shot of WD40 might solve the problem...
Linkage is fine !
In the best case, the TC mounts are loose and the whole TC has shifted to the rear of vehicle, not allowing full (inward)travel of the shift shaft when shifting into high gear.

Second best scenario (and also relatively easy to check and fix): somehow the fork's set screw (#12) broke loose and the shift shaft is moving inside the fork. Make sure the screw is firmly tightened and safety-wired.
View attachment 847600 View attachment 847601

If nothing obvious, the whole T-case has to come out and be opened, to inspect the synchronizer.
The skrew is tight and safety-wired!
My problem is the fork goes back and contact transfer case body , but synchronizer wont move beck enough to engage high range gear.
Is it possible for fork to jump out its place to back and cant move synchronizer back enough?

Thanks
 

gringeltaube

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Syncronizer (I mean the gold part in your pics) should move with fork movement ?
Yes, the whole synchronizer assembly moves back and forth, but only a couple mm each way, until the (gold colored) rings make contact with the respective gear cone. Past that travel, what really moves is the clutch collar itself. About 15mm out of neutral position, each way. Meaning that the total travel of the shift shaft should be more or less 30mm.
 
37
45
18
Location
Iran
Yes, the whole synchronizer assembly moves back and forth, but only a couple mm each way, until the (gold colored) rings make contact with the respective gear cone. Past that travel, what really moves is the clutch collar itself. About 15mm out of neutral position, each way. Meaning that the total travel of the shift shaft should be more or less 30mm.
Thanks , so thats not my problem. I hope I can fix it without taking out the whole unit 😂
 

frank8003

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All very special fasteners in there. Seek and repair all the loose stuff in there first.
 

frank8003

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HDN

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Thanks a lot !
Could loose fasteners cause the problem? (Not engaging high range)
I think that's possible. If there are loose linkages and other parts, levers and slides may not be traveling as far as they should be and things may not engage properly.


In the best case, the TC mounts are loose and the whole TC has shifted to the rear of vehicle, not allowing full (inward)travel of the shift shaft when shifting into high gear.
Is that possible with the driveshaft connected between the transmission and transfer case? I wouldn't have thought that the driveshaft had that much linear play to allow that to happen.
 

gringeltaube

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Is that possible with the driveshaft connected between the transmission and transfer case?
Yes, it is.... It doesn't take much movement (<3/16") to prevent the H-L lever & linkage from fully engaging in gear. The slip joint on that jack shaft certainly allows for much more travel than that.
 
37
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Location
Iran
Yes, it is.... It doesn't take much movement (<3/16") to prevent the H-L lever & linkage from fully engaging in gear. The slip joint on that jack shaft certainly allows for much more travel than that.
Hi
But I had opened the top 4 srews and cover and saw the fork was reach the end and contact transfer case body.

Thanks
 

gringeltaube

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Hi
But I had opened the top 4 srews and cover and saw the fork was reach the end and contact transfer case body.

Thanks
But for that to happen, the fork (and also the clutch collar) must have a lot of wear. You must have noticed that when you had it all apart, no....?
 
37
45
18
Location
Iran
But for that to happen, the fork (and also the clutch collar) must have a lot of wear. You must have noticed that when you had it all apart, no....?
Nothing wrong with them!! Everything looked like new except ball-bearings!
After rebuild transfer case worked just fine with zero problems until I parked the truck for a while and when drove it again , I had noticed the problem.
I think people who was intrested on truck and sat in the truck cause this problem.
I think they moved the lever by force to engage high range without engine runing.
Is this can cause the problem ?

Thanks
 
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