Transfercase shifter jumps out of gear

Beagle Bones

Well-known member
Oct 5, 2010
325
0
Nashville
Here's my problem. My transfercase will jump out of gear at the worst moments. I'll be mid obstacle and when this happens. I can't recall a time when I haven't had to shift back into low range. I think this happens mostly when locked in low range. Any suggestions????

It's '97 Discovery with a Rockware chassis. I'm locked in the rear w/Ashcrofts and 36" Swampers, and I've got new fluids all the way round.

Discuss.............
 

d1driver

Well-known member
Oct 19, 2005
3,153
1
Pittsburgh, PA
Get under it and lube the crap out of the linkage. Sounds like when you are locking it in, it isn't quite going in far enough. My does this once in a while. It will pop out, but when I put it back in, in seems to go in lock smoother and more definitively.

Try this.....when locking it in while the trans is in neutral, put the truck in reverse after locking it in and roll backwards a little bit while pulling the diff lock handle to the left. You should be able to feel it fully lock in. Worth a try anyways.
 

discostew

Well-known member
Sep 14, 2010
7,706
1,015
Northern Illinois
Make sure its fully getting into low range . The shifter has a threaded rod with 2 13mm nuts on either side of the lever that shifts the t-case into low range . If it's fully into low range and it kicks out then the sincro is not doing its job . Better be a really strong zip tie to fix that.
 
Jan 3, 2005
11,745
70
On Kennith's private island
The problem is most likely inside the linkage. In this photo you can see a spring and above that something that resembles a heim joint.

25847d1318186233-freeing-up-your-discovery-1-difflock-linkage-discolink.jpg

What happens is the part that looks like a heim joint breaks - the ball comes out of the socket, and since there is a spring under it the ball gets pushed up. So what's happening now when you move the diff lock lever inside the truck is it's the spring making contact with the cross shaft, and not the ball. Since the ball is larger in size, there is just not enough movement in the lever to lock the transfer case when being pushed by the smaller spring.

So an easy fix to the problem is to put a spacer above the ball so the spring cannot push it out of the socket of the cross shaft. Two 1/4" zip ties work fine.

Put the zip ties where the red arrow is in this photo.

25850d1318186233-freeing-up-your-discovery-1-difflock-linkage-discofixlever.jpg
 
Last edited:

lilmul

Well-known member
Mar 10, 2008
69
1
57
Saint John N.B. Canada
I have had the very same problem .One more thing to look at is the foam padding under the console .The foam padding can jam between the shifter and the colsole not allowing the shifter to go all the way into gear.The truck will work fine and at times under hard load it will pop out of gear.The happened to me in high range and low range.

The fix .

pull off the shifter knob and take a utility knife and cut the foam around the shifter arm.

Tony
 

Beagle Bones

Well-known member
Oct 5, 2010
325
0
Nashville
Thank you Chapman for the detailed illustration. I'll give it a look this week some time.

Lilmul, I'm certain the foam issue that you had is not my problem as I do not have a factory install any longer. I'm running a tube chassis these days as can be seen in my avatar. Thank you for the ideas none the less.
 

Lex

New member
Sep 30, 2019
2
0
ga
The problem is most likely inside the linkage. In this photo you can see a spring and above that something that resembles a heim joint.

25847d1318186233-freeing-up-your-discovery-1-difflock-linkage-discolink.jpg

What happens is the part that looks like a heim joint breaks - the ball comes out of the socket, and since there is a spring under it the ball gets pushed up. So what's happening now when you move the diff lock lever inside the truck is it's the spring making contact with the cross shaft, and not the ball. Since the ball is larger in size, there is just not enough movement in the lever to lock the transfer case when being pushed by the smaller spring.

So an easy fix to the problem is to put a spacer above the ball so the spring cannot push it out of the socket of the cross shaft. Two 1/4" zip ties work fine.

Put the zip ties where the red arrow is in this photo.

25850d1318186233-freeing-up-your-discovery-1-difflock-linkage-discofixlever.jpg
hey friend im new , i cant view the photos , my discovery 2 transfer case is popping out of high only on the interstate speeds above 70mph , thanks buddy , i hope you still have the photos , lol
 

Lex

New member
Sep 30, 2019
2
0
ga
I would be specific with Dan as far as photos are concerned.
[/QUOTE

Hey Will , dude thx for the reply , straight up that was my very first post so I am not up to snuff on how this all works so who is Dan and how do I include him or communicate with him ? (i’m assuming he’s a moderator or something like that) , it’s funny I’m actually up underneath her right now it’s Friday night 8:08 east coast time cocktail in hand and about to the snatch that inspection cover off by the selector 🤟🤟🤟🤟💪🥃🔩🛠🚬
 

CORover

Well-known member
Jun 11, 2007
745
65
Colorado, USA
I knew I should not have read this thread. Now I am having a similar issue. My lever was seized and after taking the center console out and drilling out the rivets it was easy to see the issue, major corrosion from lack of use. But now that everything is free, my lever moves side to side while in high range. It does not shift in or out, you can just move the lever.

Dan is D chapman from earlier in the post and a long time ago. If you read the dates, this one goea way back. The Internet does not forget though. You can message him directly if he has not turned that off and he might still get replies to this post. This was several versions ago so no bets on how things are working now.
 
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mgreenspan

Well-known member
Feb 28, 2005
4,723
130
Briggs's Back Yard
I knew I should not have read this thread. Now I am having a similar issue. My lever was seized and after taking the center console out and drilling out the rivets it was easy to see the issue, major corrosion from lack of use. But now that everything is free, my lever moves side to side while in high range. It does not shift in or out, you can just move the lever.

You mean like you would to lock the t-case? If it’s a D1, wouldn’t you be locking the t-case in high and if it’s a D2 wouldn’t you just be moving the lever with no adverse effects(since it isn’t connected to the CDL nipple connection)?
 

CORover

Well-known member
Jun 11, 2007
745
65
Colorado, USA
D1 high range unlocked and the lever moves side to side without changing the actual function of the lever, just moves side to side.
 

CORover

Well-known member
Jun 11, 2007
745
65
Colorado, USA
I can lock it in all four positions, it's just that the lever will move left or right if I apply slight pressure. It does not jump out of gear, I can just move the lever after it is locked in a position. Probably a detent or something has broken or come loose. I need to look into it.
 

CORover

Well-known member
Jun 11, 2007
745
65
Colorado, USA
This thread has the pics you need.