Thread: LT95 jumping out low range (at the worst possible moments)

worn teeth on the engaging dogs of low range, the rubber matting on the top of the box fouling the lever, and the linkage being damaged/fouled by debry.

Or shims/needle rollers/worn shaft on the intermediate gearset

although that normally also results in high range doing the same thing...

Could also be the adjustment on the selector forks. Might be worth checking this before dismantling. The way of doing this is to put the lever in neutral, Take the top plate of the transfer case above the intermediate shaft and make sure the front fork is in contact with input gear engaging member. There should be a clearance of 0.12 to 0.25mm (0.0005 to 0.010in) between the face of the rear fork and the rear engaging member of the input gear. If this adjustment is correct I would then look at the engaging lugs on the small (low range) gear. If there is wear there (indicated by chipped or tapered engaging lugs this could be the problem. If the adjustment is incorrect you can adjust it by loosening the pinch bolt on the selector and retightening when the correct adjustment is obtained.

Originally Posted by Blknight.aus

although that normally also results in high range doing the same thing...

If its the shims, yes, it will eventually be both, but if the lay shaft case hardening has started to come away, or the needle roller set on the low range gearset has pooed itself, it may only be low

Originally Posted by rovercare

If its the shims, yes, it will eventually be both, but if the lay shaft case hardening has started to come away, or the needle roller set on the low range gearset has pooed itself, it may only be low

Its not noisy in low range however xfer oil has a fair amount of bronze in it...

Originally Posted by Bearman

Could also be the adjustment on the selector forks. Might be worth checking this before dismantling. The way of doing this is to put the lever in neutral, Take the top plate of the transfer case above the intermediate shaft and make sure the front fork is in contact with input gear engaging member. There should be a clearance of 0.12 to 0.25mm (0.0005 to 0.010in) between the face of the rear fork and the rear engaging member of the input gear. If this adjustment is correct I would then look at the engaging lugs on the small (low range) gear. If there is wear there (indicated by chipped or tapered engaging lugs this could be the problem. If the adjustment is incorrect you can adjust it by loosening the pinch bolt on the selector and retightening when the correct adjustment is obtained.

This top plate of the transfer case - is it accessable from underneath? Is it the only removable plate apart from the bottom plate?

Originally Posted by mark2

Its not noisy in low range however xfer oil has a fair amount of bronze in it...

That will be from your intermediate shaft thrust washers. I would say a rebuild is required. Remove the intermediate shaft and inspect and replace any worn bits. At the least you will require new thrust washers,bearings and possibly the shaft. It will be the endfloat caused by the wear on the thrust washers that is causing it to jump out of gear.