I am very new to the Samuri World and to 4x4 for that matter.. Anyway I went to tow my Samuri with my MH for the 1st time and I put the transfer case in netural and than I could not get it out of netural. Waaaaaaa So I took it to the local 4x4 shop and they told me it would be $450 to replace the bushing and for all the gaskets.. Does that sound right? or am I getting the shaft?

I keep hearing about a common problem with sammies having worn out shifter sheets (or something like that), which make the tcase get stuck in neutral. It's a few dollar fix at most...

Yes, it sounds like the shifter sheet. It is a easy fix(about $12) and 15 minutes of time.  



$450 is a HUGE shaft.  

Don't bend over! Call one of the vendors here and you should have the part in a couple of days.

remove the t/case shifter and you will find a cup shaped  piece of nylon.if you replace this it will almost certainly cure the problem.as a tempory measure if you clean the nylon cup and the ball on the shifter and smear some ep90 or grease even on it it will probably be ok for a while at least.

remove the t/case shifter and you will find a cup shaped  piece of nylon.if you replace this it will almost certainly cure the problem.as a tempory measure if you clean the nylon cup and the ball on the shifter and smear some ep90 or grease even on it it will probably be ok for a while at least.

The nylon is 'washer-like'.  Round disk with a hole in it.  Tappered downward in the middle.

If the nylon isn't broken, worn or damaged regreasing it might be all that is necessary.

~Nate

I am so bummed. The repair shop has me by the short hairs. I had already told him to do the work. That was before I came here and he told me it would be at least $380 to put everything back and not do the work. I think he is lying to me but there nothing I can do. Lesson Learned. Before I do anything else I will ask here.
I would like to take the time to THANK you  

The internet is a wonderful thing if you use it right and I may be 54 but I am learning

Tell them that you want any and every old part that was replaced in the tranny, busted or not. (Old bushings/ gasket peices/ parts. everything!!! Then they dont come up with a gasket, ask them for proof that they replaced a gasket/ bushing, etc......

The tranny shops around here a f-ing thieves!!!!! They charge you triple, to do half ass work that is only warrantied for 30 days. Hell I could rebuild a tranny and it last for 30 days, and I have never torn one apart

Zig

I may be 54 but I am learning

You're never too old to learn!  I didn't start this silly sport until I was 45...

Silly Sport  Don't tell my wife,
I'll never hear the end of it  

Wild

I am so bummed. The repair shop has me by the short hairs. I had already told him to do the work. That was before I came here and he told me it would be at least $380 to put everything back and not do the work. I think he is lying to me but there nothing I can do. Lesson Learned. Before I do anything else I will ask here.
I would like to take the time to THANK you  

The internet is a wonderful thing if you use it right and I may be 54 but I am learning

So get the truck back like it is and put it back together yourself.  Check out nc_zuk's article on replacing the shifter sheet - http://bbs.zuwharrie.com/content/topic,1425.0

So many times I have heard people say  "Man my t-case is stuck. It's broke. Now what do I do?" Well it happens to every Samurai eventually. It happened to me while at the Beach. Luckily R/T was able to rescue me. I still owe you a sheet!

needed
Hammer
long skinny flat tip screw driver
pliers (maybe)
rags
NEW shifter sheet

Here is the problem
There is a round bushing inside the transfer case called a "Shifter sheet" Stock from the factory it is rubber. Over the years it gets worn and degrades from being in constant contact with gear oil. This is probably the most common problem with the Samurai. Don't sweat it.

1. Remove shifter knob
2. Remove the 4 bolts holding the t-case shifter boot to the body
3. slide the rubber boot off of the shift lever
4. Look down inside, there is another smaller rubber boot, remove this. It has a metal wire clamp holding it on but can be removed by hand or pliers.
5. now look at the silver ring around the bottom of the shift lever. It has a slot notched on each side. You will need a long skinny flat tip screw driver and a hammer here. Place the screw driver half in and half on top of one of the slots. Push down. It should go inward just a little.
6. Tap the screw driver and turn the silver ring "COUNTER CLOCKWISE" just like a screw loosens. It will turn maybe 1/4 inch and pop upward.
7. Pull out the silver ring and the spring under it.
8. Clean out all the rubber and gunk inside the t-case shifter neck (sometimes there is nothing left at all!)
9. Now get a flashlight and look down inside the t-case. There are two rods with a notch in each one. They are side by side running from front to rear. Most likely the notches are not lined up. Use that long screw driver and gently move them in line with other (the notches should form a square open box when in line)
10. Insert your NEW SHIFTER SHEET (buy a new one from any zuk vendor before you start this process. They cost about 7.00 for a rubber one and 15 for a polyurethane one)
11. Replace your shifter back into the t-case. It should fit right in.
12. replace the silver ring and spring and use the same method as taking it out to re-install it. Just make sure to turn it the other way!
13. Replace the rubber boot over the shifter onto the t-case
14. Replace the metal wire clip
15 replace shift boot and shift knob.
16 GO WHEELIN!!!


EASY AS PIE!! Takes 10-15 minutes

Are you sure the stock ones are rubber.
The stock shifter sheet I pulled out of my Sammy case looked and felt like green plastic (aka nylon/poly)

But I could be wrong

~Nate

Yes, stock Samurai bushings are rubber

Thanks for your re-plys I can see I am going to come here alot in the future and be asking questions. I am for sure coming here before I get ANY work done.

I am getting the shaft from the place that has my Zuki but what I am going to do is print out this thread and give it to them to read. After I get my car back..

Again thank you all for the in-put

Lee

buckshot......ever get an answer to your ? My forks are also stuck and can't be moved.