D300 shifting issues

[Torxhead]

For about the past 25 years or so my Transfer Case has been getting harder to shift into any gear. It has a twin stick w/4 to 1. I'm thinking it is somewhere in the internal shifter rails. Has anyone had any similar issues? I am not to familiar with the internals of the Transfer Case .

 

[Lumpy Grits]

When was the last time you ck'd/changed the oil?
LG

 

[Torxhead]

LG, pretty recently checked, and the oil, 80w-90 dlr oil, does not have that many miles on it either. The Transfer Case is not rotated. Are you suggesting that a dirty oil could cause this issue? Rather than a Transfer Case removal, I was wondering if I could just drain the oil and pull off the front off to get at the internals.

 

[Lumpy Grits]

Can you re-install the OEM shifter?
LG

 

[Torxhead]

Long gone LG. I just might have to take it to a shop.

 

[Flex BT]

The last 25 years or so? Have you tried using foul language against it? Usually works for me when combined with a slow roll & full clutch depression.

 

[Dan77CJ7]

Torx, Did you do a full split?

 

[hole]

Torx. Mine was pretty difficult before the rebuild. With the stock single stick it was a huge fight to get in or out, then it got better when I twin sticked it but still some fight. After the rebuild/ 4-1 upgrade it shifts like butter, even with the stiffer detent springs. What I believe was all the trouble was dirt/ packed between the shift rail cap and the shift rail seals. I mean it was packed full of dirt. It wouldnt be too hard to pull the twin stick and then the shift rail cap to see if thats your problem

 

[Torxhead]

That dirt possibility sounds like a good one Hole, it seems like the Transfer Case has to come out to remove that shift rail cap due to the shift forks being in there. Dirt does seem to find its way into a CJ.

 

[hole]

Well, I did do mine on the bench but you shouldn't have to pull the rails, just the cap that goes over the rails. IIRC its one 5/16 bolt that holds the cover on, and the dirt was packed between the cap and the seals. You do have to completely remove the shifter assembly, then the cover should come right off unless I'm forgetting something.

 

[Torxhead]

O.K., so the rails stay in when the cover comes off. Sounds like a seal replacement is needed. Might have some worn out rails though.

 

[Lumpy Grits]

Won't know till you open it up.
Good luck,
LG

 

[hole]

The seals are in there pretty tight, might be pretty difficult with the rails still in place. You have to pretty much disassemble the Transfer Case to get the rails out. Mine were original and showed no sign of leaking, just a load of dirt packed on the outside of the seal. After you pull the cap, a stiff toothbrush and air hose ought the get 98% of the crud out. Might also try a light shot of penetrating oil on the rail at the seal before putting the cap on.

 

[Torxhead]

Pulling that cap for an inspection sounds like a good plan.

 

[hole]

I hope its as simple as that. I saw no other reason why mine shifted hard.

 

[Torxhead]

Update: Well I took the Transfer Case into a local shop that has a real good reputation for gears. It was disassembled and nothing obvious stood out other than it was hard to shift. No dirt got past the seals on the shifter rails either. So I stuck it back in and the 2wd,4wd high and low side is pretty smooth now but the other side, high, neutral, and low that has the Tera-Low shift rail is still a bit stiff. I was told that the early versions of this 4 to 1 kit did have issues. When I purchased the Tera-Low was the only one of its type, along with the Currie twin stick. So I guess i'll just deal with it.

 

[hole]

Glad to hear it wasnt anything too bad. I've never seen a Currie twin stick set-up, but I've heard it uses adjustable linkage, could something have shifted over time so that it's no longer a straight push/pull on the shift rails? Just throwing potentially worthless ideas around

 

[Torxhead]

Currie Enterprises CJ Axle Parts
I am pretty sure Currie was first to make them, and at about half the price they are now. The company is local, so I bought it direct. The JB one does look tempting, but the CJ has a few other issues, like not spending enough time on the trail.

 

[Hedgehog]

A least one other guy had trouble with that twin stick set-up. Bolts were binding or something similar. Looks like way to many parts that could possibly go wrong to me. I think, with a close look at the JB set-up it would be easy to convert yours to the JB system.

 

[Torxhead]

Hedge, I think I would have to see that JB twin stick mounted in a CJ and get my hands on it just to make sure. They do have pretty shift knobs though.