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 Crawler Gear Install
#906335
09/20/08 03:08 AM
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Joined: Aug 2000
Posts: 4,868
OP
Roll Me Over
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I have just finished (?) the installation of my Revolution 3.1 (nee Terralows) in my '91 Trooper, manual tranny. Due mostly to my lack of motivation, I have been working on this periodically for 11 months.
I finally got everything buttoned up today and pulled the rig out of the garage. Everything works EXCEPT I can't move the lever into 4-lo. 2-hi works as does 4-hi.
I had tested everything prior to putting on the rear portion of the case, but neglected to test it after the case was re-installed.
I really don't know where to start.
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Re: Crawler Gear Install
[Re: Jim_Paget]
#906336
09/20/08 06:05 AM
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Joined: Apr 2000
Posts: 7,268
Isuzu Moderator
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I really don't know where to start. Take the transmission back out. <img src="/forums/images/graemlins/smile.gif" alt="" /> Either you have the wrong rail (I know, I know, we talked about this, but it is still possible). or you dropped one of the detent balls into the great abysss and the shift rail cannot move all the way forward. Good luck, michael
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Re: Crawler Gear Install
[Re: Jim_Paget]
#906337
09/21/08 02:42 AM
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Joined: Jun 2000
Posts: 3,702
Roll Me Over
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Can you move the control lever to the 4lo position at all?
Steve Carlson - 95 Trooper LS expo rig
Serenity now!
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Re: Crawler Gear Install
[Re: BigSwede]
#906338
09/21/08 03:49 AM
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Joined: Aug 2000
Posts: 4,868
OP
Roll Me Over
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No, I can't move it at all. I did discover a bit more today.
When I installed the rear portion of the case, I had the lever in 4-hi as directed. I did check as I was installing to make sure that the front output was not disconnecting. It was connected through it all, and in fact I had to move the lever back to 2-hi in order to turn the output so I could install the front driveshaft. However, I can no longer move it to the 4-hi position.
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Re: Crawler Gear Install
[Re: Jim_Paget]
#906339
09/21/08 09:53 PM
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Joined: Jun 2000
Posts: 3,702
Roll Me Over
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I wonder if you didn't get those "dogteeth", or whatever they are called, that sit in the "High-low synchronizer assembly" (my shop manual's term, basically the hi-lo clutch hub) in correctly. I had a heckuva time getting those assembled right on mine.
Another thought, does the shifter lever work with the cover off?
Steve Carlson - 95 Trooper LS expo rig
Serenity now!
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Re: Crawler Gear Install
[Re: BigSwede]
#906340
09/22/08 12:58 AM
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Joined: Aug 2000
Posts: 4,868
OP
Roll Me Over
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That will be the next step to pull the tranny again, but that will have to wait for a week when I have some time off again.
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Re: Crawler Gear Install
[Re: Jim_Paget]
#906341
09/22/08 02:52 PM
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Joined: Jun 2000
Posts: 3,702
Roll Me Over
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I did mine in the truck. Not sure at this point I'd pull the tranny if I were you; I had the cover on and off my t-case about a dozen times before I got it figured out (air rachets rule!).
Steve Carlson - 95 Trooper LS expo rig
Serenity now!
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Re: Crawler Gear Install
[Re: BigSwede]
#906342
10/02/08 01:23 AM
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Joined: Jan 2000
Posts: 1,232
Body Damage is Cool
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The early 5-speeds are the most in depth install. They have the most parts you have to deal with.
The only set that I installed that had a similar issue was when I was doing a '97 and I had the wrong shift fork. It had very similar issues. Its been a while, but I'm pretty sure you need the -4 shift fork.
In any event you are going to have to pull the t-case. It isn't too bad to work on while it is in the truck.
1987 trooper LS.'94 3.2, SAS,35's , lots of dents and rust. Now, improved, with more dents.
1995 trooper LS. Wife won't let me improve this one.
1996 trooper. I'll need something to modify when the '87 finally rusts away.
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Re: Crawler Gear Install
[Re: Chad Hunter]
#906343
10/02/08 01:27 AM
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Joined: Aug 2000
Posts: 4,868
OP
Roll Me Over
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I went ahead and pulled the tranny. It really wasn't a big deal since all the bolts and nuts were nice and clean. I haven't had a chance to dig into the beast yet.
When you say shift fork, do you mean shift rod? The fork should be the stock fork, shouldn't it?
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Re: Crawler Gear Install
[Re: Jim_Paget]
#906344
10/02/08 01:53 AM
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Joined: Oct 2001
Posts: 4,016
Isuzu Moderator
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Yes, its the shift rail that caused issues early on. The one that ended up working in my Amigo (5-speed, slip-yolk) was the -4 mentioned above.
Sean Strawmyer Back and ready to rock...... crawl. From Indiana or surrounding states and interested in wheelin'? Check out www.mwior.com
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