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

[Biggerhammer]

Bump For anyone needing it.

[wflaw45]

thanks allot for this post, i got the part and just dont have the time to put it in. i have a body lift tho so this might be a bit harder

[zukmike]

Nah..  the body lift wont make it any harder. I got a 3" lift on mine..and I replaced mine in about the same amount of time. 

[NC Zuk]

I received another e-mail about this article, this time from Romania

[muskyslayr]

Great write up on the stuck transfer case.  I ran into this situation once when towing my zuk.  Once I got to where I was going I went to put the tranfer case back in gear...fergit about it...wouldn't move.  So what'd I do?  I signed onto Zuwharri and bingo bango.  You guys are great...I just wished you were closer to the great white north.

[sammi_davis]

  You guys are great...I just wished you were closer to the great white north.

No offense but we dont ...too durn cold up there 

[muskyslayr]

aw c'mon...it aint that cold up here.  I'll send in some pics of winter wheelin this winter.
I might even put the top on...ha ha

[ka4yqi]

aw c'mon...it aint that cold up here.  I'll send in some pics of winter wheelin this winter.
I might even put the top on...ha ha

I too old and blood dont flow as well for that.

[KEITH13]

I just picked up an 88 samurai for 250$ and it had this problem, after I pulled the shifter out the only remains of the sheet were a black goo around the edges.  And I also wanted to ask about the transmission problem??? Will those worn out parts prevent me from even putting it into gear?

Thanks
Keith

[supazuk]

www.trailtough.com is in Washington state and www.roadlessgear is in Oregon Both sell them

not to nit pick but trail tough is in medford Oregon and roadless is in Montanta

[NC Zuk]

Got another e-mail on this today so I thought I would bring it back to life

[dirkj]

Hey Guys!

I recently had a similar problem but with a different cause and solution.  I think it might be worth posting here incase it ever happens to someone else.

As with the Australian guy, the problem struck me late on a Sunday evening.  I had the Zuk in 4wd and when returning to the road and 2wd mode the t-case suddenly got stuck in "neutral".  It wasn't going anywhere.  As it was way too dark to look for the problem, I had to get a towtruck to take us (my wife and two dogs included) home.

Fortunately I was able to use my wife's car the next day to get to work and back.  That evening it was time for a little digging under the car.  I got in there flat on my back and removed the shifter etc from the t-case.  I felt and looked around but couldn't find anything wrong for quite a while.  Then it suddenly dawned on me that the silver ring part (removed in step 9 of the original post) was not looking so well.

The two little "bayonette"-type pieces were bent downward causing the shifter assembly to slip out of the t-case just enough to keep it from operating properly.  The shifter would go in where it should, but the minute you try to shift it slips out.

I used a simple pair of pliers to bend it back (close enough) into place.  The metal doesn't seem to crack or break easily, but it is quite hard and strong so the repair should last (although I do plan to rather replace the part sometime soon).

Voila!  This time it clicked in properly and holds down the shifter where it should be.  In fact, in all the time I've had my Zuk, my t-case has never shifted so well so this problem might have been a long time coming!

Hope this helps someone out there!

Regards,

DJ

[lance981]

Another big Thank YOU for this post!
We were leaving our CG Hosting stint in a remote campground in New Mexico. My wife drove the Zuki out and I drove out our truck camper. When we got to pavement we stopped so that I could hook up the Zuki to tow it. She move the t-case to neutral. I connected the tow then got back in the Zuki to check everything. Damned - I couldn't get the t-case out of neutral!
Fortunately it was OK to tow, so I took off for the nearest civilization (Bloomfield, NM). I figured that the t-case was toast. After we got settled in a Campground with Internet access I decided to check this board for the heck of it to find out if anyone else ever had the t-case stuck. Low and behold a search found this thread.
I called Petroworks, ordered that part sent UPS 2nd day to one of our next stops (Dubois, WY), followed the instructions on the post and I'm back in business.  YEEHEE!!

[lacrosse10604]

Does this work on Track/Kicks? I can only shift into neutral, 2nd and 4th. I'll post my question else where if need be...

[Ballenxj]

Another great write up!  I've heard of this problem before, and now I know what to do if/when it happens to me.
Nice to know Your article is helping folks all over the world. 
-Bruce