Transfer Case, Loss Hi Gear

[samnt650]

After a brief run in sand, my transfer case wont get out of of Low Gear.. Checked the top end (shifter) and appeared nothing broken (yes I have pull apart the top and side cover) I can see the locker cable move in/out.. having difficult finding where is the Hi/Li lever on the transfer case.. wondering anyone encounter this problem??

 

[Clark Kent]

After a brief run in sand, my transfer case wont get out of of Low Gear.. Checked the top end (shifter) and appeared nothing broken (yes I have pull apart the top and side cover) I can see the locker cable move in/out.. having difficult finding where is the Hi/Li lever on the transfer case.. wondering anyone encounter this problem??

I don't recall anyone reporting a loss of high range. It's possible that driveline wind up is stopping you from shifting out of low range. Drive in reverse while making some steering inputs for a short distance to unwind the driveline. Attempt to shift out of low range again.

The selectors are up high on the LHS of the transfer case. Follow the two cables in the area above the steel cooler pipes. I doubt you can get to them but might be able to look for movement when the shifter is operated.

 

[DustCloud]

I've had it jump out of gear moving from Low to High on a couple of occasions (always on the center-diff locked side), then moving from N to D. When this happens there's a sort of neutral on the transfer case between high and low which sounds horrible. I have the impression the actuator mechanism is poorly adjusted and the lever reaches some sort of stop before the lever which is reached before the transfer case is properly engaged in high range. On my list to mention to service agent...

 

[samnt650]

Actually found the problem The Hi-Low cable broke at the transfer case lever. It was absolutely PITA to push the lever back to Hi gear.

 

[Clark Kent]

Actually found the problem The Hi-Low cable broke at the transfer case lever. It was absolutely PITA to push the lever back to Hi gear.

Well that's not good. Other reports of broken cables here.
How did you move the selector lever at the transfer case. Any pro tips now that you have done it?

 

[samnt650]

Its a two person job. Truck needs to be on Neutral (engine running) and one person need to be under the truck (you arm is on the exhaust, trying to reach the top of the transfer case at the rear, not ideal) and do whatever you can push the lever toward front of truck, pop it back to Hi Gear. Best to be on incline, allow the truck to roll a bit. That helps pushing the lever in place.

 

[Clark Kent]

Its a two person job. Truck needs to be on Neutral (engine running) and one person need to be under the truck (you arm is on the exhaust, trying to reach the top of the transfer case at the rear, not ideal) and do whatever you can push the lever toward front of truck, pop it back to Hi Gear. Best to be on incline, allow the truck to roll a bit. That helps pushing the lever in place.

Its a two person job. Truck needs to be on Neutral (engine running) and one person need to be under the truck (you arm is on the exhaust, trying to reach the top of the transfer case at the rear, not ideal) and do whatever you can push the lever toward front of truck, pop it back to Hi Gear. Best to be on incline, allow the truck to roll a bit. That helps pushing the lever in place.

Thanks for the feedback. I'm tossing around some candidate scenarios for a write up of roadside recovery actions for a new section of @Rok_Dr's guide. The type of stuff that comes up in the SOS section so it's at hand if you have a copy of the guide. I want to say this one is too obscure and not worth prepping for but it's not the first cable to break so it might be worth a mention. Cheers.

 

[samnt650]

I'll try to get some pictures (when the truck is in the shop) for the repair instruction..

 

[samnt650]

@Clark Kent Let me know if you need the originals

 

[Clark Kent]

@Clark Kent Let me know if you need the originals

Thanks @samnt650.

My vehicle is currently at my agent for warranty replacement of the Steering Column Module (SCM) so I haven't had access to it to work on this.

The red callouts will disappear in a printed copy. If you wouldn't mind posting the originals then @Rok_Dr can add callouts using your markup as a guide.

Please confirm the direction of the range selector lever on the transfer case: Forward is High range and rear is Low range? That's consistent with your 19 Jan post.

 

[samnt650]

Posting the original here...
For the High Low gear lever >> move toward the front = High toward the rear = Low
For the Transfer Lock >> move toward the front = Unlock / open toward the rear = Lock
For the transmission neutral lever >> move toward the ground, and find a way to hold it there = Neutral
For the Transfer case neutral >> Turn clockwise