Transfer Case, Loss Hi Gear

Thanks @samnt650, good pics.

Agreed @Clark Kent more thought or experimentation is required to determine the feasibility of it all.

Cheers
Steve

Good photos. The port near the rear output flange looks to be oil out to the cooler. I could be wrong, looking at the casting the t/case may have a pump driven by the rear output and the return oil from cooler returns higher up the case lubricating the whole gear set. There was another post showing an Ineos diagram of the t/case and cooling lines and it didn't appear to have an external pump in the diagram.

samnt650 said:

Pic 1 / img 7543 - You are correct. Left of pic is front of the truck.
It is possible to shift Hi Lo, Lock Unlock with engine off (we can do that w/ the shifter) That was something I couldn't achieve while under the truck. The Hi Lo & Lock Unlock lever requires force to move.

I think pull cord is easier help move the Lock Unlock lever. With the Hi Lo, its going to a challenge moving it to the Hi position

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A follow up for those watching on.

I spent some time this past week laying under my vehicle trying to come up with a simple and repeatable method to access the high - low range lever on top of the transfer case so it can be manually shifted in the event of a cable separation or failure off-road - as was @samnt650's experience in this thread. It's a no from me.

It's too difficult to get access between the transfer case and the heat shields under the body to get something in there to apply enough force to shift the lever. This is in consideration of the dexterity required in a tight space surrounded by hot (probably) and sharp surfaces. I mean, it's clearly do-able and @samnt650 has some great skills likely fuelled by his desperation to get home, but it's not something that can be captured in a do-it-this-way procedure.

The best takeaway from this investigation is the knowledge and pics of where the high-low lever is located. Run your hand up the back right side of the transfer case. Lay your hand flat and feel forwards across the housing and you'll start to feel the lever and cable bracket.
If you find yourself in the same situation you may be able to sort something out, otherwise drive out in low range to a recovery spot.

The 2nd pic has psychedelic vibes that confuse me!

Tazzieman said:

The 2nd pic has psychedelic vibes that confuse me!

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the picture disappeared from your post

samnt650 said:

the picture disappeared from your post

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I think @Tazzieman is referring to my 2nd pic with the 60's vibe coming off the heat shield. It probably reminds of his University days. Well, the ones he can remember
This pic...