Ever had your Transfer case "Stuck?" Here is how to fix a stuck t-case

[NC Zuk]

So many times I have heard people say  "Man my t-case is stuck. It's broke. Now what do I do?" Well it happens to every Samurai eventually. It happened to me while at the Beach. Luckily my buddy R/T lived nearby and was able to rescue me. MY HERO!! I still owe him a new shifter sheet!

Here is the problem
There is a round bushing inside the transfer case called a "Shifter sheet." Stock from the factory it is rubber. Over the years it gets worn and degrades from being in constant contact with gear oil. This is probably the most common problem with the Samurai. Don't sweat it. It is quite easy to fix!

For ease of understanding and a better view, I did this article with the t-case out of the vehicle. There is no need to pull the t-case out of the vehicle to do this.

Items needed
Hammer
long skinny flat tip screw driver
pliers (maybe)
rags
NEW shifter sheet

Let's start out sitting inside the vehicle.

1. Remove the transfer case shifter knob. (it just unscrews)
2. Remove the 4 bolts holding the rubber t-case shifter boot to the body.
3. Slide the rubber boot off of the shift lever and set it aside.
4. Now, Look down inside the hole, you will see another smaller rubber boot. You will need to remove this. It has a metal wire clamp holding it on but can be removed by hand or pliers. You may have to crawl under the vehicle to reach the ring but I never have needed to. See the pics below.




5. Once you remove the wire clip you can peel the rubber boot up and remove it from the shifter lever.



6. Now look at the silver ring around the bottom of the shift lever. It has a slot notched on each side.



7. You will need a long skinny flat tip screw driver and a hammer here. Place the screw driver half in and half on top of one of the slots. Push down. It should go inward just a little. You may need to push down on both sides of the silver ring.





8. Tap the screw driver and turn the silver ring "COUNTER CLOCKWISE" just like a screw loosens. It will turn maybe 1/4 inch and pop upward.





9. Pull out the silver ring and the spring under it.





10. Pull out the shift lever and set it aside.

11. Clean out all the rubber and gunk inside the t-case shifter neck (sometimes there is nothing left at all!) There is usually a small flat rubber washer still in good condition that sits on the bottom of the hole. Remove this too.



12. Now get a flashlight and look down inside the t-case. There are two rods in the very bottom with a notch in each one. They are side by side running from front to rear. Most likely the notches are not lined up. Use that long screw driver and gently move them in line with each other. The notches should form a square open box when in line. If you find that you can't get the rods to budge, try having someone rock your vehicle fore and aft. Sometimes the drivetrain will be so bound up that it takes a while to get the rods into position. Just don't give up!





13. Insert your NEW SHIFTER SHEET (buy a new one from any zuk vendor before you start this process. They cost about 7.00 for a rubber one and 15 for a polyurethane one) I chose to use a polyurethane one as they last forever!





14. Replace your shifter back into the t-case. It should fit right in.

15. replace the silver ring and spring and use the same method as taking it out to re-install it. Just make sure to turn the silver ring the other way!







16. Replace the rubber boot over the shifter lever.

17. Replace the metal wire clip

18. Replace shift boot and shift knob.

19. GO WHEELIN!!!


EASY AS PIE!! Takes about 20 minutes!

[Jigsaw]

I would just like to add a side note to this. On alot of suzuki transmissions ( 5 speed models). That same piece in the transfer case he is talking about will go bad resulting in what you can say is best described as over shifting. Basically for example when you shift into second it goes in fine but it wont engage the gear b/c you have actually shifted past it b/c of the piece being bad.

[R/T]

actually Josh, that is a different piece, the shifter sheet is in the transfer case that shifts from 2wd to 4wd hi and 4wd lo.
 The piece that causes the over shifting or loose shifter is a shifter alignment bolt in the neck of the transmission shifter which keeps the shift lever tight.
R/T

[Jigsaw]

Interesting to know. I was shown the piece you are describing ( round piece) and was told that was the culprit in the trannys as well b/c it kinda lets the shifter drop. Had that problem go wrong in my Jeep as well. Total cost to fix was around 5 bones.

[R/T]

it could be now that I think of it, never had the problem. I'll look into it later this week and get a full report! thatnks for the correction!
R/T

[NC Zuk]

it could be now that I think of it, never had the problem. I'll look into it later this week and get a full report! thatnks for the correction!
R/T

Ya know, I had one of those go kAPOW as well. Luckily I had a spare tranny to rob. It looks different and mounts ontop of the shift ball but it was nasty all the same. They have replacement poly ones for about 20 $.

[Robzuk]

 If y'all want to make broken shifter bolts a thing of the past send your tower out to Sarge at Midwest Performance. He adds a second locator bolt eliminating the broken bolts and stiffening up the shifter. I got a 1994 that was stuck in neutral CHEAP!
ROB

[the4x4xgirl]

Hey, if you're really in a bind and need to get your rig back on the road again, head down to Lowe's or Home Depot to their Plumbing departments.  They sell rubber/vinyl slip washers that with some slight trimming around the edges will replace the old worn shifter sheet.  

[the4x4xgirl]

Oh yeah, its like a $1 for a bag of 2.

[yoothgeye]

Thanks 4x4 girl!

[beachrebel429]

Thanks, never know where you'll be when it goes out>>

[NC Zuk]

Well, I can't believe this. I just got the following e-mail form a guy in Australia. Makes it worth the time to write this how-to out!!

I also did a google search on the net for "Stuck t-case" and this article came up first 

Deep gratitude

I want to give you a big thank you for your article on
getting the t-case (un) stuck.

I just bought my Suzuki on Friday night, and the
family and I drove around in it all weekend. But late
on the Sunday night I got the t-case stuck and I had
no car to get to work (3 hours each way by bus/train)

I searched on the internet for some clue on how to fix
it when I found your article. I followed it
step-by-step from a printout under the (dull) interior
light at 11 pm last night . While I did not have a new
shifter sheet to put back in the car, I did manage to
get it unstuck and get to work today.

Your article saved me an enormous amount of hassle and
probably expense!

Thank you so much

Your new friend in Sydney

Craig Pollard

[Biggerhammer]

Way to go!

[SPAMurai]

I hope you replied and invited him to join us here!  Sounds like an interesting guy.
Steve O'
Art - Will be in Fay later this week for work at a site off Morganton Road.  What's your schedule this week?  Time for lunch one day?

[NC Zuk]

Oh, I never miss an oportunity ti invite someone tpo the bbs. Heck, I search out other bbs's, join them,  and then post about this one