I took the Sammy down to the lower backyard, which involves a 40% slope. so obviously 4W low.  I loaded up all the crap I needed to get up, then calmly motored back up said 40% slope.  At the top, on level ground, I unlocked the hubs, then TRIED to shift back into 2W, to no avail.  Stuck in t-case neutral with a stick that didn't do anything.

Quick trip to the inter-web, where I rapidly learned how to pull the lever and move the shafts with a screwdriver.  Back in 2W and all is well, but I DID order a new bushing, hoping this won't happen again.

Regardless, I've been thru this (at first) panicy nightmare, and now I know the drill.  It only feels like the end of the world when the wife pulls up, the Sammy is stuck in the front yard and not moving, and you have no idea how to fix it, and she's pissed about it.

Anyway, 10 minutes on the internet, a $14 part, and maybe this won't happen again.  But like I said, if it does, I know the drill.

that happened to me out wheelin had to get a tow truck...not a fun day for me

I had the same thing happen to me but I was with a bunch of jeep guys and did not know about the screwdriver thing.... Well I pulled out my T-case right there on the trail and took it apart..... Well I got towed home! I was not happy but I did get a rebuild out of it.

can some one post a link to the screw driver fix? I did a search but I guess I suck at the search thing. I want to view it as a prevenetive measure in case this ever happens to me. Thanks .

Just buy a brass shift seat and pull the shifter out from inside the car.Take out any of the old bushing and drop in the brass one. Re-install the shifter and your good. If you wait untill it's stuck, then with the shifter out, use a large screwdriver or tire iron and move the round shift rails untill they move free. Then re-install the shifter. If it does it once, it will keep doing it.

Had this happen to me out on the trails,I kinda knew what to do with a tire iron.BUT it still sucked!!Also had a Samurai that was stuck in 1st gear!! Not a problem for the mudholes...until you NEED to back up,which is like every 5 seconds!Got that shift sheet in there,then traded it for a '90 Jeep Cherokee four door sport 4x4.

No pictures but a better how to

Remove interior plate and boot. Reach down and slide dust boot off of shift tower and pull it up the stick. Using two long screwdrivers push down and rotate the silver locking cup CCW. When it releases you will see that it popped up about 1/4" at that time you can pull stick out easily.

Look down the tunnel and see 2 rods. Driver side is 4L N That is the one that usally sticks from a worn out poly or rubber bushing. What you want is the two rod slots to make a square, so take a long screwdriver and get that driver side rod to move out towards the engine. Sometimes it goes easy sometimes you have to have the rig in gear and someone rocking it back and forth to relieve the gear load. Once it pops (one of the dentent balls has gotten in place it shouldn't be) you wil now be able to make the square, put the stick back in and drive away. Installing a brass shifter sheet is the best. After years and years of use they still show no wear. For the same price it makes sense to go that way.

MY

For Pictorials, go to Ack's FAQ (see link in signature, below) and do a search for shifter sheet.

The pics will help illuminate My's excellent post, above.

How common is this Dreaded Tcase scenario?   I have the worlds worst luck, and sometimes I'm tens of miles from the nearest person or cell phone coverage area.    Pretty sure this will happen to me.

Fixed Blade,it will be alright...just drive your Samurai and dont worry 'bout this n that could go wrong.

How common is this Dreaded Tcase scenario?   I have the worlds worst luck, and sometimes I'm tens of miles from the nearest person or cell phone coverage area.    Pretty sure this will happen to me.

It happens to every Samurai, sooner or later.  It should only happen when you're moving the transfer case shifter...it doesn't just pop into neutral randomly. 
Its easy to pop back into gear...even on the side of the road.  After you've done it once, it just takes a few minutes. 
Best to spend a few $$ on the brass shifter sheet and prevent it from happening in the first place. 

Note that if your t-case mounts are a bit twisted through either heavy wheeling or a transfer case gear set your shifter can sit really close to the front of the tunnel when in 4-low.  Then a good bump or hit can cause it to try and pop back into neutral and then get stuck.

If your wheeling your Samurai I would recommend picking up an aftermarket cradle, or just welding a piece of angle iron to the inside of the long mounting bracket to help it hold up a bit more.

Note that if your t-case mounts are a bit twisted either heavy wheeling or a transfer case gear set your shifter can sit really close to the front of the tunnel when in 4-low.  Then a good bump or hit can cause it to try and pop back into neutral and then get stuck.

Yep...and this problem is exaggerated if you have a body lift.