Transfer box lever stuck, can't shift into low range.

[Paulmc]

Since getting it back from the gearbox garage my transfer box lever won't move. After all the trouble I've had with the garage I am reluctant to take it back so trying to find the issue myself if possible.

It won't move at all, its in the normal position high range. I have taken the centre console out & removed the lever to have a look but the rods seem jammed. Is it possible to refit the transfer box incorrectly causing this issue?

 

[knicko]

I know when I had a 90/95 series, if there was anything worth knowing, Bob Murphy would have covered it on this forum.
I recall he did a thorough write up about the auto box/transfer case and I also recall him saying there was something particular about setting up the selector rod when putting it all back together.
Try searching on Bob's past posts in the 90 series forum and I'm sure you'll find the answer you need.
Good luck!

 

[knicko]

In fact, here's a link that might be your answer...

Transfer Box Problems

Very Recently got a 1997 Land Cruiser Colorado 3.0 TD overall she seems like a good old thing however the shifter for the transfer box is stuck in H. for the time being this isn’t a problem because I’m not in any hurry to use her round the farm. The box has oil in it and on inspection seems to...

www.landcruiserclub.net

 

[BobMurphy]

Hi, I'm still here .

The usual problem is that the end of the Transfer Lever misses the slots in the selector shafts.

Your Transfer Box is in the "High Ratio, Centre Diff Unlocked" position. I usually take a large screwdriver and click the right-hand selector back into the "diff locked" position - where the two slots line up.

Its easier to locate the Transfer lever then.

Give that a try, if it still doesn't work I'll think again.

Did the garage take the Transfer Box apart ??

Bob.

 

[Paulmc]

Thanks for the help guys.

I did infact try to move the right hand rod back with a large screwdriver but didn’t want to force things as it seemed to be jammed. How much resistance should I feel when trying to move it? Also I should do that with the auto box in neutral correct? Should the engine be running when trying to move with screwdriver as I had the engine off, although I can’t see why that would make a difference?

Also I tried refitting the lever making sure I located the end into the slot. I’m assuming the end on the lever should go into the right hand slot? Anyway it still wouldn’t move & I tried with engine running, auto box in neutral & also as the manual says while driving (I tried at low speed) still not moving. When I first removed the lever the spring inside was loose & I don’t thing the lever was located so I initially thought it was that.

I don’t see any rust either, it all looks very clean & well lubricated & I even gave the rods a spray with a spray lubricant.

As for did the garage have the transfer box apart, I do not know. I can’t see why they would buy who knows & probably won’t tell me the truth anyway!

 

[BobMurphy]

Right, you are not going to like this . . . .

Reading your other posts it seems your garage are somewhat clueless and I suspect they have made a blunder with your Transfer Box (TB) while it was out.

I'll dig out some pictures . . .

At the rear of the TB, top side, there are two plugs with Hex sockets in them. Inside here are a pair of springs (nested - the small one is inside the larger one) and a 'detent ball'
These click into notches on the rear of the selector shafts to provide a positive registration when the various positions are selected.

Worse - in between the two shafts is an 'Interlock Plunger' that prevents the shafts from selecting the wrong combinations of functions. I.E. you can't select 'Low' with the centre diff unlocked . . . .

What I think has happened (I've done it myself) is that someone has pulled the right-hand shaft too far forward and the detent ball has jumped in behind it - jamming the shaft.

This is easy to do on an Auto TB as the selector shafts stick out of the front, on a Manual they are inside (where you have a blanking plate).

This is the arrangement inside . . .

This is what the ends of the shafts look like (you don't have to strip the rear cover, speedometer drive or Companion flange):

The 'fix' is to:

1. Remove the TB.

2. unscrew the two detent plugs and tip out the contents - as above (you may have to move the right-hand selector shaft forward a bit).

3. With the RH shaft pulled forward, re-insert the interlock plunger:

4. With the TB tilted to the left, move the RH selector shaft back and re-fit the Detent balls, springs and plugs to both sides (this can be fiddly).

5. Check that all functions work - without pulling the RH shaft too far forward, or you will be back to 'Step 2' .

6. CAREFULLY re-install the TB and check it over.

7. Warning - the TBs weigh 50 Kilos so not an easy lift from underneath whilst lying on your back (DAMHIK).

Good luck, let us know what you find.

Bob.

 

[BobMurphy]

Paul,

You could try the following - without removing the TB - You may get lucky:

1. With the TB installed, remove the Right-hand Detent plug.

2. With a small magnet on an extending shaft - try to draw out the two springs and the ball (make sure that the Interlock Plunger remains in place).

3. Click the RH selector shaft back into the 'Diff Locked' position.

4. Re-install the ball, springs and plug as I showed previously.

5. Test it out.

This may not be possible with the TB installed without a body lift as the transmission tunnel is a bit tight. It might be worth a try though.

Best of luck.

Bob.

 

[Paulmc]

Hey Bob, thanks for all the help. Makes sense as to why I can’t move the shaft now. I really don’t have the facilities to do it on my own & it’s bloody cold outside.

I’m going to have to take it back to the garage & speak to them. Problem is I’m using it for work each day & can’t afford to be without it. Absolute nightmare this whole experience has been, I can believe it though as the muppet who fitted my gearbox was clueless. They had subbed a mobile mechanic to do the job due to their staffing issues!

I’ll keep you updated on the progress. Don’t suppose you know of a good Toyota specialist close by to the midlands, I’m going to need to use someone I can trust going forward?

 

[BobMurphy]

Paul,
My explanation is an "Educated Guess", it could be something else (but I can't think what unless they stripped the TB).

I can't help with testimonials for Engineers in the Midlands - I'm just outside Edinburgh . I'm sure someone will be along soon with a recommendation.

I hope you get it sorted, it sounds as though you have been messed about a lot.

Best of luck.

Bob.

 

[Buller]

Paulmc, is Gloucester too far away from you?

 

[Paulmc]

Well it’s a little far but would depend on what I needed doing I suppose & if the place is any good.

 

[Buller]

Give Roger a ring at White Posts garage in Gloucester. He may be able to help. He got my auto gearbox sorted after it kept slipping out of lock off

 

[Mikeinbris]

Wow that was a lot of useful info, thank you bobmurphy!!