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95 sidekick, 4 lo popping out of gear!!!

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kickscrawler91

95 sidekick, 4 lo popping out of gear!!!
« on: January 20, 2008, 01:08:32 AM »
When I am in 4 lo my transfer case will just pop in to neutral at random times, under acceleration, at idol, and coast. Does anyone have any ideas? I am waiting for it to pop out during some serious wheeling.  :o
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Offline museboy07

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Re: 95 sidekick, 4 lo popping out of gear!!!
« Reply #1 on: January 20, 2008, 07:40:17 AM »
I have that same problem on my 94 track.  I figured out the problem by taking the stock t-case boot out and making my own.  It seems that the stock boot was being used as a rubber band and when i tried to shove it into 4lo  it just popped right back out.  But after i made a custom boot it hasn't happened since.
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1994 Tracker, 2in Ironman springs w/ 1in spacers on top, soon to have custom diff drop brackets, 31x10.5-15 All Tarrains, Pro Comp long travel shocks, KYB performance struts, strut mount flip w/2in extensions, 3in rear a-arm spacer, ...DD
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Offline locjaw

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Re: 95 sidekick, 4 lo popping out of gear!!!
« Reply #2 on: January 20, 2008, 09:43:21 AM »
body flex as well as the boot can make them pop. even if it looks like you have enough clearence , you may not
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1995 Sidekick SAS'd "Trail Slayer"
1993 4 door lifted "Road Warrior"
1995 4 door stocker "CreamPuff"
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Offline KickTurn

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Re: 95 sidekick, 4 lo popping out of gear!!!
« Reply #3 on: January 21, 2008, 09:01:22 AM »
I have the same problem on my 95 sidekick, and it's not the boot-- I ran it with the boot removed, and it still popped out of 4-low.  The shifter doesn't contact the floor cutout, and I've changed the tranny bushings.  I pulled the transfer case and took it to a good tranny/transfer case shop, and they haven't found any issues with the case itself.  I'm as mystified as kickscrawler91.
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95 Kick JLX 4x4 4dr 1.6 16v. 
235s, manual hubs.
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Offline KickTurn

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Re: 95 sidekick, 4 lo popping out of gear!!!
« Reply #4 on: January 21, 2008, 03:54:28 PM »
locjaw, if the problem is body flex, what can be done about it?
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95 Kick JLX 4x4 4dr 1.6 16v. 
235s, manual hubs.
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Offline Drone637

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Re: 95 sidekick, 4 lo popping out of gear!!!
« Reply #5 on: January 21, 2008, 07:27:09 PM »
Trim the body so it no longer flexes into the shifter.  :)
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96 Geo Tracker, x-SJ-410,  x-White Rabbit, x-Project Trouble
Crawlers NorthWest
x-Trouble Racing
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