Thread: LT95 transfer case jumping out of gear

The thrust washers between the gears on the intermediate shaft are buggered. It can be fixed without removing the box.
RR

Not familiar with linkages in a county (have a 101) - so modify the following as appropriate. The first obvious thing is to check is that you were actually in hi range - sometimes you get a false lock-in, that causes it to jump out later - move to Hi, then move the car a little and then ensure the lever is fully engaged - will often move a bit ensuring a positive engagement. (mine still does this - so each change in hi/lo is a two stage affair with the initial change - then a second move to ensure it is locked in).

Second obvious thing is to check the adjustment of the linkages/cable. This can cause the gears to lock in but to later pop out.

If linkages are OK the next place to adjust is the internal adjustment in the box (was the problem with mine). The forks are in a central cross shaft operated by the external linkage/cable. The fork can come loose a bit and move on the cross shaft so the linkages turn the cross shaft but this may not result in full movement of the fork to lock the gears in. Remove the top rectangular plate on the top of the tfr case and the fork is right there. Move your Hi/Lo range selector to Hi (making sure it is in the correct position as far as it will go). Loosen the bolt that secures the fork to the cross shaft and move the fork to the hi range position by hand - then simply tighten the bolt in the fork to secure it to the cross shaft. Problem should be fixed.

If the problem still exists then you will need to look further in the transfer case as has been suggested.

Cheers

Garry

Originally Posted by County3.9

My transfer case jumps out of high range (originally started to do it when taking off in reverse, now does it when accelerating or cruising, I haven't noticed it jumping out when backing off).

Does anyone know what would cause this and where to start looking?

Forgot to add that often it will jump back into gear on its own...frightens the **** out of ya!!!!

If you have the standard intermediate shaft assembly, as said it is more than likely linkage adjustment or worn thrust washers (most likely). If you have the Tapered roller bearing intermediate shaft possibly worn bearings/adjustment. Both can be rectified in situ............Brian

Originally Posted by Red Rocket

The thrust washers between the gears on the intermediate shaft are buggered. It can be fixed without removing the box.
RR

^^^^, Drain the oil and look for pretty bronze flek in it

I just wrote about this in the 'Loud Bang' thread... but that related to the the transfer box alway having jumped out of gear, rather than recently starting to do that.

I assume someone smarter than I could search for a post of mine from about mid winter last year where I had a pdf attachment with some photos of the machined recess in the housing that became the silastic trap and caused all the trouble.