Thread: low range "falling out"

Depends what the problem actually is.

The possibilities I can see are:-

1. Missing, broken or weak detent spring (under screw cap on top of transfer case in line with high/low selector shaft; Simple, easy to fix. But unlikely to be the problem.

2. Linkage loose or something stopping it going in fully, could be selector fork loose on the selector shaft. Drain the oil, remove the bottom cover, and see if the gear is fully meshing, and if not, why not. (This enables you to see 3,4,5,6 as well)

3. One or more teeth on either the sliding or intermediate gear (or both) is damaged. Replace. Can be done in situ, as can other transfer case repairs. This is the most likely problem

4. Free play on bearings, most likely the ones on the output shaft, but possibly the intermediate shaft. The output shaft bearings can be adjusted with shims, but the intermediate shaft bearings (and possibly the shaft) need replacing.

5. Excessive end play on intermediate gear probably due to a missing thrust washer. (unlikely)

6. Worn selector fork (unlikely)

Note that there could be more than one of the problems noted, most likely excessive free play on the bearings resulting in tooth damage.

John