Preamble…Last time we were out 4-wheeling, I had a problem with my transfer case shifter (the one for 4WD). We had been blazing around in some deep snow and when it came time to shift back into 2WD the shifter was jammed. It had been a little difficult to shift previously but I had put it down to lack of familiarity with my new bus and the shift pattern on the knob was incorrect (aftermarket shifter). I tried for all I could to get the shifter to move but it wouldn’t so we decided to continue along the snow covered road to a spot where we could have lunch. During lunch I tried again and the shifter ended up breaking inside the transfer case. Crap! This left me stuck in 4WD-Locked and, faced with the fact we would be going back to hard pavement, the decision was made to pull the shifter out and attempt to manually shift it out of 4WD-locked. With the help (and tools) from other members, we managed to get the t-case shifted into the AWD mode which can be used on hard pavement and reassembled so the group could carry on playing for the afternoon.
As it turns out, there may have been an underlying problem that was causing the difficulties leading up to the final failure of the shifter. Here I would like to document the replacement of the shifter assembly and how to resolve the issue should anybody experience the same problem I did.
The fix…The shifter replacement (and in-field repair) can be done from inside the van. No need to drop the transfer case out of the van. Firstly, if you are doing this in the field, be highly aware that any bolts and washers removed can easily be dropped through the opening in the floor to the ground so it is a good idea to lay something underneath to catch them (especially in snow).
Remove the shifter knob… it just unscrews from the top of the shifter lever.
Under the carpet, there is a metal plate with 6 bolts (10mm) which will need to be removed. In my picture, I had left the grey shifter boot off from the field repair. Normally, the bottom of the boot would be fitted under the metal plate. Remove the metal plate and the shifter boot.
- 1- Stick remova.JPG (149.96 KiB) Viewed 2145 times
- 2- Stick removal.JPG (161.25 KiB) Viewed 2145 times
There is a second black rubber boot that seals the hole in the floor of the van. Pull this back out of the way. It stays on the shifter assembly. This will reveal the top of the transfer case.
- 3- Stick removal.JPG (159.75 KiB) Viewed 2145 times
To remove the shifter assembly from the transfer case, you will need to remove the 4 bolts (12mm) on the larger of the 2 plates. DO NOT remove the 3 nuts on the top triangular-ish shaped plate as these 3 bolts could fall inside the transfer case if they happen to be loose.
- 4- Stick removal.JPG (49.19 KiB) Viewed 2145 times
This picture shows my problem… the lower tab had broken off of the stick inside the transfer case. The break appeared as though it had been cracked for some time and I assume it must’ve bent when I shifted into 4WD the final time and caused it to jam and subsequently break.
- 5- Yup its broke.JPG (32.82 KiB) Viewed 2145 times
If you are stuck in the field and need to get your bus shifted back into AWD or 2WD mode, it can be done with a screwdriver. In the picture, the front of the van is to the left (driver’s side at the top). Pushing the linkage towards the front of the van will get you out of the locked positions and into AWD or 2WD so you can drive it home. You will still need to re-install the shifter prior to driving home though.
- 6- Manual shifting.JPG (59.58 KiB) Viewed 2145 times
More to come...
