I kind of agree on the interlock thing. With the shifter removed, I would try to move the 2wd/4wd shift rail back and forth and then try the hi/N/lo rail again while pulling 2wd/4wd either direction. The other thing I'd try is removing the shift detent springs and balls and trying again. This is stuff you should be able to do outside w/o pulling the t-case. You'll probably need a FSM to figure out what bolt/where to remove though.

Also, if there is gear grinding sounds when you try to shift back to 4-hi, then its probably not the shifters and probably has something to do with the shift collars inside. You could have broken a shift fork or something and its not sliding the collar evenly and therefore doesn't want to engage...?

One great resource to call would be Marlin @ Marlin Crawler. He may have heard of something like this happening before. I remember reading about something similar with the (v6?) transmissions that if they get jarred at a certain point they can get stuck in a gear (reverse?). I think usually that happened when the tranny was out and set on end though. Your jerk in reverse maybe could have done something similar.


'97 4Runner, '06 F350, '86 4Runner, '05 WR450
http://home.4x4wire.com/erik