Transfer case slips out of 4x4

[wyo58]

Sadly it gets worse as they also had slip yoke tail shafts on some of the larger vehicles, could be a long one or a short one as well. I'm right there with ya on the old part Tiha!

 

[wyo58]

Update: with the Rabs module un-plugged it made no difference, it still pops out in 4wd high. I have one more thing to try and I will let you know if it works.

 

[wyo58]

Okay so what I did was to cut power between the module and the shift motor leaving all power supplied to the module alone. In park with the manual hubs locked in, engine off key in the run position I pushed the 4 wheel drive button, I heard the shift motor shift to 4wd. the 4x4 light came on then I killed power to the shift motor. Started the vehicle and it stayed in 4x4 and all the lights stayed on which they should. I drove around for about 30 minutes and it stayed in 4x4 the whole time. It usually would pop out on coast slight down hill. It never did so for whatever reason the module is supplying power one way or the other slightly and spinning the shift shaft just enough to be in between producing a neutral condition. Why it is doing it I have no idea, but the problem is definitely electrical. After the test I placed it in park shut the engine off, reconnecting the shift motor terminals, then key to run position pushed the 4wd button to take it out of 4wd, then released the hubs to free. Started the unit up and checked to make sure it was in 2wd. So I believe that there is something faulty in the shift module that is causing the problem. I'm seriously thinking about installing a double pole, double throw relay on the shift motor lines on the module so that I can **** those wires after the initial shift in and out.

 

[wyo58]

To add to the above post I also killed the wire to the magnetic clutch coil as well so all three were cut after it was shifted into 4wd. So if I do it I will use a three pole, double throw relay to be able to disconnect all three wires at once.

 

[wyo58]

Update to other updates, Took it on a longer drive on a dirt road in 4wd with all power off of the shift motor and coil. It still pops into neutral, so it has to be mechanical inside the transfer case. Keep in mind it is a reman case and is doing exactly as the original case was doing. I am calling the re-man company tomorrow and ask them what the problem could be, I'll post here when I find out.

 

[Tiha]

Oh that sucks doesn't it. You spend so much time troubleshooting and think you are headed in the right direction then bam. Nope.

Sorry, but at least you are still making progress. Great work!

 

[wyo58]

I talked to the company I purchased the re-man from to see if they had any idea or had seen this before. They have not seen this particular problem before. He said it has to be the range clutch though or I would be having issues in 2wd as well. He said he will do more thinking and ask around to see if anyone else has had this kind of problem and call me back if something comes up. Also he offered to send a call tag for the t case to send back so he could look inside for what's going on with it. So I might take him up on that if I can find the energy to take it back out lol. I'll keep all posted here.