Thread: 4 speed tranfer problem

Originally Posted by peterlr

h i
my transfer box is stuck in low range
the selector shaft is sliding in and out sideways about 1 inch and doesn t appearto be engaging with the selector . can i take the plate on top off-8 bolts and access the works without tking out the seatand floor etc?-being lazy
have rebuilt a series 3 tranfer but this looks another level
peter

G'day Peter, it sounds like the plastic spacer on the transfer case cross shaft has fell apart and this allows the cross shaft to move sidewards and the selector finger comes out of the jaw assembly. Just to get it out of low range and functioning again see if you can push the cross shaft back to the passenger side while jiggling the hi/lo lever in the approximate low range position. You will feel it when it slides back in. An easy fix for this without dropping the box out is to add some washers onto the outside of the shaft on the passenger side and then a split pin to hold them all there once you have it back in place. This stops the shaft moving back to the right and holds the selector finger in place. The proper fix is to undo that plate on the top rh side of the transfer case. You then have to loosen the pinch bolt holding the selector in place and move the shaft towards the passenger side just far enough to slip a new spacer in beside the finger and then move it back towards the drivers side and back through the housing. You didn't mention what vehicle it is, a civvy Isuzu 110 or an ex army perentie - the civvy one has the linkages on the drivers side and the perentie has it on the passenger side. I am guessing civvy if the shaft will move that far so you will have to remove the roll pin holding the hi/lo lever onto the crossshaft when you want to put a new spacer in there. Have fun!!

thank you Brian
excellent reply -what i needed. I think it is a"civvie",only had it about 5 years after driving aseries 3 for 25 years
Am finding it harder to do work mostly age tho I think
but I found the S3 easier to contemplate cos I culd relatively easily remove transfer and fiddle-the LT95 seems daunting out on the drive at my age
thanks again peter

Originally Posted by Bearman

G'day Peter, it sounds like the plastic spacer on the transfer case cross shaft has fell apart and this allows the cross shaft to move sidewards and the selector finger comes out of the jaw assembly. Just to get it out of low range and functioning again see if you can push the cross shaft back to the passenger side while jiggling the hi/lo lever in the approximate low range position. You will feel it when it slides back in. An easy fix for this without dropping the box out is to add some washers onto the outside of the shaft on the passenger side and then a split pin to hold them all there once you have it back in place. This stops the shaft moving back to the right and holds the selector finger in place. The proper fix is to undo that plate on the top rh side of the transfer case. You then have to loosen the pinch bolt holding the selector in place and move the shaft towards the passenger side just far enough to slip a new spacer in beside the finger and then move it back towards the drivers side and back through the housing. You didn't mention what vehicle it is, a civvy Isuzu 110 or an ex army perentie - the civvy one has the linkages on the drivers side and the perentie has it on the passenger side. I am guessing civvy if the shaft will move that far so you will have to remove the roll pin holding the hi/lo lever onto the crossshaft when you want to put a new spacer in there. Have fun!!

Thanks Brian, this should go down as a legendary fix for LT 95's.

In my case (C9 happily mated to an LT 95 TC) all was good for a couple of years, then stuck in Hi range. Not an urgent problem.

When I had time I had a look at the roll pin (by removing the stock handbrake boot), roll pin good, and noticed the sideways movement you described above.

Then I thought the bolt holding the finger on the shaft had come loose, so was planning a rainy day job cutting another hole in the floor to access the top plate, haha.

After reading your post this morning, and having a spare LT95 to look at, I found the right size washers and split pin and 10 mins all done!

In my case I could get the finger to re-engage by holding the Hi Lo lever to the left (and watching it through the handbrake boot hole in the floor) making sure to get Hi, Lo and neutral, before fitting the 2 washers and split pin.

Exactly as you described.

cheers, DL

Happy to help out 350. If LR had made a decent spacer (metal instead of plastic) this would never happen and also likewise for the rubbish plastic stuff that is on the end of the hi/lo selector finger. Both fall apart after a few years and you end up with this problem. When I rebuild a box I use an alum spacer and use some reinforced plastic fuel line on the transfer finger. It takes the slop completely out of the lever and gives you a really positive feel when you shift range. And the spacer will never fall apart.

I dare say that the plastic spacer in mine has been an 'oil additive" for a couple of years.

Rick 130 would know the benefits.......... or otherwise haha.

DL