1996 5 Speed Transfer Case Issue... 5 Questions

[nursemcdonald]

Hey there Here is the follow up I promised, yet I need some help with this!!

The mechanic received the T-case I had shipped directly to him (which he said was in immaculate condition). The only difference in the new and mine was that the new T-case had 2 electrical 'plugs' where mine had absolutely nothing... everything matched up, so he installed the new one which fit like a glove.

On road test, everything shifted very smoothly and quietly... UNTIL you tried to shift into LOW RANGE!

It is impossible to shift into NEUTRAL or LOW RANGE....

So now what?

1. was the part correct? Other than a complete mechanical match, NO.
2. is the new one electrically actuated to allow a shift from High Range into LOW? I dont know...
3. IF SO, what signaled the T-Case to allow a shift from High to Neutral to Low?
4. could/should one place a modified switch to manually overide the actuator and allow me to shift into Low range...?
5. What would be the correct part number if I were to search for a new t-case that was not electically actuated...?

Help please?

 

[BaldEagle]

none are "electrically actuated", the automatics have a solenoid that has to be getting power from the brakes to shift it. he was suppose to do something with the lockout solenoid. i know its possible and simple, my 5 speed has an automatic tbox. i did not do the work however, im sure someone here knows exactly what to do with it. but dont worry, as long as something isnt wrong with the box, it will work

 

[nursemcdonald]

If no electrical actuation, then why the electrical terminals on this unit?

So then the real question is how to disable the lock-out solenoid?

Thanks

 

[BaldEagle]

by actuator im thinking you mean a motor that shifts it......i think you know thats not true....i know disabling it is easy, i just havent done it. surely someone, PT for sure, here knows how. its done all the time. the wires go to the solenoid, and i know there is a switch for the diff lock indicator that has wires also.

 

[nursemcdonald]

I understand that when removing and replacing the transfer case the "low range" should be selected... what would happen if this is not performed?

Im beginning to think that there is an issue with the way the linkage was installed, as it is IMPOSSIBLE to put the transfer case into NEUTRAL. A shiftlock should at least allow you to go into NEUTRAL?

 

[BaldEagle]

umm no, it keeps you from shifting at all.........but you still may be right with the linkage.....ive removed the linkage before from inside the truck, and it was a bitch to get it back in the right place. i had to ride around the block several times to get it right before i put the console back together. wait until someone says how to fix the lockout and find out what your mechanic did before we tackled the linkage. if your mechancic had to guess how to bypass the lockout, thats my guess.

 

[nursemcdonald]

Alrighty!

I reopened the case, and ran current through the electrical connection. The lockout released and shifting was smooth and easy.

SO, Said to my self: why dont I just remove the damn thing; just as someone posted a reply to another inquiry I had.

The solenoid was removed and problem seems resolved!

You can find a PIC of the solenoid in another thread entitled: Solenoid Lockout Bypass

Thanks BaldEagle for your time and consideration,

Ryan

 

[BaldEagle]

no problem. i just remembered what to do when you said you removed it......thats exactly it. glad you got it