ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: Patsy on March 24, 2007, 10:34:53 AM
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I am trying to overhaul my '86 Samurai T-Case.
I've removed it from the vehicle but the shift lever won't come out.
The retainer has been removed but when I pull the lever up it hits something hard and won't come out.
It doesn't make any difference which gear it's in, although it's really hard to find neutral or 4WD low.
The shifter sheet must be gone because the lever wobbles all over and shifting is vague.
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try pulling up hard on it while shifting it into neutral if you know the pattern.
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Tried that.
Removed flange and front case bolts. The case can be separated about an inch.
Looked in with a mirror and flashlight and saw bottom of shift lever all gouged and bent.
I don't know how to get it out without destroying the front case or the shift rods.
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what about rigging up a slide hammer on it.
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I've thought of that.
I'm afraid it may bend the shift rods.
Which is the cheaper fix? Using the slide hammer and replacing the shift rods (assuming the forks are not also damaged) or breaking off the end of the front case and replacing that.
I may just get a used T-Case.
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you might try turning it left or right. the allignment pin may be broken letting it turn.
if you force it out it could break but its allready broke right? make sure the shifter is pointing the right way
(http://memimage.cardomain.net/member_images/1/web/2581000-2581999/2581996_5_full.jpg)
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The shifter is able to spin 180 degrees if I push it down.
The flange will go down below the pins. I'm pretty sure of which way it is supposed to go because one way the lever hits the case when it goes into 4WDH. So I think the lever is supposed to go the other way.
I've tried it both ways. I know the sheet bushing is totally gone. You can push the lever down past the pins. I suppose plastic from the bushing could be jamming things up some. But the sound it makes when trying to jerk the lever out is definitely metal to metal.
The T-case came out of a sammy I just bought. I drove it in 2WD and it seemed OK but I couldn't drive it in 4WD because it had little tires on the front and big tires in back. And no dirt or gravel handy. (why would somebody do that?)
So the case seemed to work. But the shifter didn't have a pattern. The stick wobbled all over.
You could shift pretty easy from 2 to 4H. But 4L was hard to find and neutral was real hard to find.
When I peeked into the case with my mirror the bottom part of the shift lever was badly gouged and looked to be bent.
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Can you remove the shifter tower and take the lever out with it?
http://www.hawksuzukiparts.com/images_parts/part_shifterfix.jpg
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thats a tranny shifter he's having trouble with t-case
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oh, ... I shouldn't be allowed to wrench on cars.... nevermind...
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If you can rotate the shifter itself 180 degrees and you can see the bottom of the shifter rod is bent pretty badly, then you might try rotating and wiggling the shifter until the bottom end of it can clear the shifter rods enough to come out. The shifter end fits into a box formed by notches in the sides of the shifter rods. If the two rod notches are lined up with each other then you will have a box hole twice as big as the end of the shifter leaving plenty of room for the end of the shifter to move.
If this does not work, I would suggest tearing the entire tcase down. It probably needs it anyway. I am not a proponent of violence on jammed equipment. It usually leads to more damage.
I believe that the previous owner, discovering that the t-case was "locked" (read: the bushing had disintegrated) used violent force on the shifter itself causing the end of the shifter to bend. The shifter rods may already be distorted which probably locked the case into 2wd mode.
T-cases are kind of rare finds as folks tend to buy them, regear them and then resell them. You can still find a good one reasonably priced if you look hard enough
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Thanks for the replys, so far.
I found another T-case for a reasonable price and it doesn't seem to need rebuilding. So I can get back on the road.
I do intend to find out what's going on in my old case. It looks like I may have to break the end off the front case so I can get it apart.
I wonder hard hard it will be to find another front case for the T-case?
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when the shifter sheet goes out and the t-case locks up . alot of people unjam it by force. thus breaking and bending things. i carry an extra shifter sheet in the glove box. easy to fix. takes about 20 minutes. hope your new t-case works good
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Carrying an extra shifter sheet sounds like a good tip.
I replaced the shifter sheet in my new T-case with a new plastic (polyurethane?) bushing.
The original bushing was almost gone. What do they make those things out of? Silly Putty seeems as durable.
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actually i think i have 3 extra