‘94 tcase overhaul

[86customanche]

I’m fairly certain I need the transfer case over hauled, and I’m positive I don’t have the time nor ability to do it. 

For the past year the 2wd/4wd linkage wouldn’t budge and has been stuck in 4low. Last week while in reverse there was a clunking sound and now there are no working gears. 

I can shift through all 6 positions but nothing happens nor sounds when letting out the clutch. 

Can someone ball park an overhaul? Thanks. 

[MuddFoot]

You could get a junkyard case for 75-150 and swap it in. I think you might have just popped into neutral in the tcase.

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[yxmj]

Have you tried just removing the linkage at the t-case .....and using a set of vice grips to shift it.......maybe just your linkage is fubar?

 

If stuck in low.....maybe the thump was it going into neutral..... That would be why you have nothing 

[kook911]

On 11/12/2018 at 4:44 PM, 86customanche said:

I’m fairly certain I need the transfer case over hauled, and I’m positive I don’t have the time nor ability to do it. 

For the past year the 2wd/4wd linkage wouldn’t budge and has been stuck in 4low. Last week while in reverse there was a clunking sound and now there are no working gears. 

I can shift through all 6 positions but nothing happens nor sounds when letting out the clutch. 

Can someone ball park an overhaul? Thanks. 

 

 

Doing this yourself is not very had at all.  I did mine not to long ago and it was easier then I thought.  Just followed the write ups and you will be fine.  As in the cost depends on what needs to be overhaul.  They sell a kit on kit on ebay that comes with the chain and most of the seals and bearings give or take $110-$140.  If your needing the other parts then it might be cheaper to get a good used one.  You really won't know till you get it off the rig and take it apart.  But either way the old tc will have to come off.  

[86customanche]

The linkage was removed a year ago when it wouldn’t leave 4L, a failed attempt to fix it. Now that the tcase appears to be in neutral I’m going to try vice griping again or reinstalling the linkage. Maybe I’ll get lucky.....

[86customanche]

With a little bit of force I was able to vise grip the tcase into 2wd and then move the manche under its own power. It drove well around the yard in 1st and 2nd. 

Next I’ll reattach the linkage and see how it works. 

More than likely when the owner son is home for a week in January we’ll be over hauling it, any suggestions for a good reliable kit?

[schardein]

I've had the linkage be out of adjustment.  Not because the linkage moved, but because the engine mounts and transmission mounts have settled over time, and the result was when in 4 low, the transfer case would pop out of gear.  The fix is to adjust the linkage.

 

However, I found the linkage was rusted together and would not adjust.  I had to completely remove it to be able to work on it on a bench and get it to free up.  Once done, I reinstalled it, and adjusted it.  No more issues and shifts smoother than it ever has since I owned it.

 

Side note, it was a huge pain to get the shifter mechanism out, because the screws that go into the body stripped out/broke the welded nut loose from the body.  It took me more time fighting the stripped screws to get it out, than freeing up the rusted together shifter adjustment.

 

I eventually replaced the engine and trans mounts, and then re-adjusted the linkage again, still shifts good and doesn't pop out of gear.

[86customanche]

I was able to reattach the linkage and shift from 2wd to 4H, and then with great difficulty managed to shift to 4L but it soon popped into neutral. It appears that 4L is not working well, I’ll play some more with it but expect the overhaul will be happening the first week of January. 

[yxmj]

Since you say you don't have the time and skills to rebuild.....why jump to rebuilding immediately?  Try the basics first....if they don't work....then do the surgery...as mentioned above...make sure the linkage is beyond clean and adjusted correctly.

First basic thing you could try is .....drain the fluid....clean the magnet......fill it up with new (cheap) atf....drive it a bit running it in 2....4....and 4 low......drain the cheap fluid.....clean the magnet......now top it up with good quality atf.....that might be the fast wash it needs.

[86customanche]

Good idea, though first I need to research the “magnet”. 

I’m the keeper of the Manche while owner son is out of state. Basically I run it every few weeks to keep it happy, going on 3 years. 

Skills are slow coming, last year had to replace fuel pump. 

[yxmj]

Depending on what has been done the magnet might be attached to the bottom drain plug....

[86customanche]

Wow, I just checked the fluid level and couldn’t feel any with extended pinkie finger in the hole, and this was with truck on slight incline nose up. 

I’ll drain and fill in the next few days. 

 

 

[86customanche]

A couple of days later........ the owner tells me he never checked the fluid. So I remove the drain plug and nothing comes out. I then filled it, ran it until warm while exercising the gears, then drained and filled again. 

It definitely is much happier with fluid, still a little stiff to change tcase selection but the manche is again usable. 

I’ve got cardboard under it now to check for leaks. 

 

Thanks yxmj for the fluid suggestion!

[zomeizter]

It's amazing how long these T-cases live without fluid in them, dealt with this many a time when I was wrenching-for-a-living. Most of the time, replacing the seals and refilling would get them back on the road. A few times we saw some over heated bearings but never a catastrophic failure, but then again, most were pavement queens...