T-case problems. <img src="/forums/images/graemlins/barf.gif" alt="" /> This Amigo is being stubborn.


Rear output was locked up tight,couldn't turn it to line up splines in clutch.

When shifted into 2wd the front output turns free,the rear is locked up.

4wd hi front/rear are locked solid.

4lo front and rear turn smoothly like normal.

Pulled the rear case off last night.

No metal or such inside.

Moved shifter,2wd fork moves up and down smoothly,engageing and disengaging front output.

Problem is that the fork for hi/lo will not move down enough to disengage the low gear,so it has both engaged.

The fork needs to move down about 3/16" to fully ebgage.
There is that much space under the "dog" on the shiftrail
for the rail to move.
That clearance and the fact that fork moves with the rail,I don't think rollpin is broken on the rail.

I removed the ball/spring for endant? To make sure ball didn't break and wedge under the rail,not letting it move down more.The rail needs to move down 3/16" to allow ball to engage.

I didn't see anything broken or chipped,all bearings/pcs. move smooth.

I raised the shift fork(hi/lo) up as far as I could,and all pcs look good,are smooth and the synchro pcs are all lined up.

So what's next?


By down I mean forward,the case is resting on the bell housing,The tranny moves and feels smooth in all gears.
Different gears and neutral do not effect the tcase.

SOrry so long,thanks.

Bansil

Is this a new case?

Can you turn the 4wd low gear independently on the main shaft when it is shifted into 2hi?

Michael

what about checking the torque spec on the stake nut holding the hi-lo assembly? for some reason, i recall if this was overtightened, you might produce something similar to what you are describing? maybe?

-Rob

No this case has probably atleast 100k on it.It came with the Amigo.

I'm alittle confused.
When it's in 2wd the sliding "collar" on the main shaft doesn't go down far enough to disengage the "main gear assemble?

The large gear on the output shaft meshes with the middle gear(idler?) and the front output gear at all times,right?
When the case is removed,the large output gear comes off
with case.

With the case off,everything spins as a unit,all three sets of gears spins as a unit.
This includes the hi/lo set(even though "the sliding collar" looks like it needs to move down.

With the case off:

I can shift into lo-range,the fork comes up,moving the "collar"up and ingages the teeth on the output gear(the one in the case which is removed,and slides up enough to disengage the gear on the bottom(high?)


The assemble looks like:

a coned brass bushing,part of synchro's,then there are metal teeth(lo-gear?) under the synchro,and then another steel ring about 1/2" thick that looks like a timing gear,then under that is another set of metal teeth(hi-gear?)
followed with another brass synchro?

The "collar" that the shift fork moves is about 3/4" thick.

When the t-case is shifted into 2wd or 4wd high the "collar" moves down,but it is thick enough to engage both synchro's and both set's of metal teeth,'thus locking hi/lo gear together.
When the fork moves to lo gear it moves enough to fully engage the low gear "metal teeth" and disengage the High gear "metal teeth".


wow clear as mud.........sorry for the fancy terms <img src="/forums/images/graemlins/smile.gif" alt="" /> but I don't have a manual at work.

Bansil

So what is the background information on this problem? Was everything working and then this just randomly popped up as an issue; or was the case taken apart and put back together and now this happens? Stock or Tera Lowed? Is the 4Lo gear in its proper orientation? There may be an associated thread that I'm not aware of <img src="/forums/images/graemlins/confused.gif" alt="" /> Did you remove the 4wd sensor and check the lock-out pin/spring?

This T-case has stock gears as far as I know,we got the amigo with the t-case tranny installed already,it was supposed to be good.

After looking at the case and talking with Bigpoppax2....
I removed my Donkey ears.......it is not going into low gear with the case off.

I went to install the engine and tried to turn the driveshaft to turn the input shaft and line up the clutch disc splines,I noticed the rear shaft wouldn't turn,I tried to move the t-case lever and make sure it was in gear,2wd had the rear shaft locked,it wouldn't turn.The front shaft spun freely though.I moved the lever to 4wd.It locked the front shaft but neither shafts would spin.I moved the lever back to 4lo and both shafts would spin.
When I tried 2wd again,the rear shaft was locked up and the front shaft would spin freely.

So I pulled the tranny/tcase and installed the engine and am now trying to figure out why the t'case won't work.

With the rear case off,I noticed the collar was engaging both the hi/lo gear,moving the shifter wouldn't fully engage the low gear and unlock the hi gear.

I will pull 4wd switch and check the interlock this weekend.

If interlock was bad/broken etc.Would it still work both shift rails?.The 2wd rail/fork works fine.

I will call the person,I got it off of and try to get some more info.

Bansil

Good... it shouldn't be. <img src="/forums/images/graemlins/smile.gif" alt="" />

Look at the Hi/Lo engaging "ring". There will be some surface before the 'valley' the shift-yolk sits in and some surface after the valley as well. One of those surfaces should have another, smaller valley (or groove) machined around it... and that surface should be toward the back of the case. I don't know if having it the other way (small groove toward the front of the case) changes the throw of the ring or not; but its worth looking at to make sure its on the right way. If it does change the path the ring travels and someone had it off and put it on backwards, that could be the issue.

You already said the roll pins are not broken. If the case has never been apart, its hard to imagine anything else that would change the path that ring travels. Do you know the guy you bought it from well enough to trust that he would tell you the truth about the case being tinkered with?

Ok,I took the t-case completly apart saturday morning.

The needle bearing in the lo gear was completly rusted to the collar/inner race.

This effectively locked lo range in all the time,since it couldn't freewheel.


Does anyone know the part numbers for the bearing and collar?


There is no rust on any shafts or gears.......very weird.

Thanks

Bansil

Ah, the needle bearings strike again. That's what I just got done replacing... my fault, though, as I had a small leak for awhile and let it go too long and starved the bearings. The needle bearing and a new 40mm staked nut for the mainshaft was $36.88 through St. Charles. I didn't have to buy a new collar (amazingly). Don't have the part numbers anymore; I already tossed my receipt.

This effectively locked lo range in all the time,since it couldn't freewheel.

I'm a little behind on my response, but you just figured out why I asked what I did. <img src="/forums/images/graemlins/smile.gif" alt="" />

Michael