Transfer Case problem

37
45
18
Location
Iran
Here are the troubleshooting steps in PDF format. Unfortunately the text can't easily be copied and pasted into a translator, so I hope you're able to manually type the text into one or know enough English (or have a friend that does) to get through them!
Thanks a lot !! I know English enough to understand technical text 😁
 
37
45
18
Location
Iran
Hello everyone

Can I just take out front compounents of transfer case (like drive shafts and etc) and open front door for repair ?

Thanks
 
37
45
18
Location
Iran
You may be able to remove the lid alone. But then, getting all shafts back in place at once will be challenging, at least.

Have you found already what causes the synchro to not fully engage?
I'm still searching . But I think the fork is out of its place.

Taking the hole unit out is challenging too!!😁
 

gringeltaube

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...... But I think the fork is out of its place.
.... or the whole input shaft has somehow moved backwards a couple mm??:?

Before you pull apart the whole TC, here are a few dimensions you can check and compare with yours, after removing that top 4-bolt cover (plus the poppet ball, stem & spring) ....
  1. For fairly new parts, the synchro collar is 17.5mm thick and the groove in the fork is 18.3-18.4mm wide. So there you have a total play of 0.8-0.9mm. It can be felt by moving the shift shaft in-out. (it appears to be more than that, in this pic, but it really is less than 1mm)
Fork on clutch collar.jpg Almost new1.jpg Almost new2.jpg Fork groove.jpg

2. Free (back-forth) movement of the whole synchro unit is little over 2mm, between both gears. Past that, you start compressing the spring-loaded clutch collar of the synchronizer.​

3. Total travel of the collar - out of neutral, and up to complete engagement, after stopping against the gear's face - is about 14mm. The synchro itself allows for 15mm travel of the collar, each way. Synchro- and gear dogs start making contact after the first 5mm of travel.​

4. With the fork perfectly centered in Neutral, the distance measured from the backside of the fork to where it would contact the housing is ~20mm. So, if all was normal, there is plenty of room left for a full engagement, without the fork touching the case.​
5. With the set screw tightened in place, the distance between backside of fork and first groove of shift shaft is ~19mm. (below pic) That means that when the shaft/fork assembly is in Neutral, that first groove should just appear visible, out of the bore in the housing.​
backside of fork to 1st groove.jpg
I would also unscrew the set screw and check that it is in good shape. Compare with pictures below.....​
Set screw in shaft hole.jpg Set screw tip.jpgSet screw, tightened.jpg
 
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