Hey guys I am new here and a new sami owner. Don't know alot about suzukis so I thought I would come here and ask. When I first got this 95, the transfer case would not shift. just real tight and would not change. Then I finally jacked with it a bit and now it is stuck in never never land. It will go in reverse but thunks, forward gears sound likke they are not engaging completely. Took the assembly off and cannot move the shifter at all even with it out.  As I rotate the rear shaft I hear the front shaft begin to try to engage but doesn't. Drained the fluid and it smells burnt. Any thoughts? I appreciate the help.

Is it a 1995 Samurai or a Tracker?

samauri

Nice, we don't get many that new...

It sounds like your t-case is stuck in neutral.  With your shifter pulled out can you use a large screwdriver to move the shift forks manually?

not in neutral, and after changing the fluid I can get the shifter to move to the various gears. But there is slack and the forward gears grind a bit when you let out the clutch. the reverse does engage and does not grind. the slack is in the front diff. coming from the transmission.

oh yeah,  the shifter would not pull out of the transfer case after removing the container and the spring.

SHIFTER SHEET

Your bearings could be going out also,Those have sealed bearings in The later models If I remember correctly, the Gear oil is just for the Gears That Year.

SHIFTER SHEET

That could cause the shifting problem, but even with a bad sheet he should be able to pull the shifter out without any issue.

Actually, I can't think of a good reason for the shifter to not be able to pull out...