Need transfer case diagnostic

[rbunch4468]

My CJ with T-4 and Model 300 transfer case acts like it is in neutral. The shifter 'feels' normal. I am in the process of taking the top cover off of the tranny to see if I can see anything unusual. The transfer case shifter moves, but I can't tell if the transfer case is getting driven from the transmission. I can shift through all four gears, and t-case ranges without any difference. There is no movement at either drive shaft.

How can I diagnose whether or not my problems are with the transfer case, short of pulling it out onto a bench, and going through it?

Engine runs fine....No unusual noises in clutch or transmission shifting and releasing clutch.

What inspection process should I use to narrow this down? Any ideas?

Thanks,

Rick

[ZAEDOCK]

Rick, you forgot a couple of details as to how it became this way; http://www.jeepforum.com/forum/f8/trann ... l-1024441/

At this point, you should just take the 1/2 hour (max) to disconnect the diveshafts and 6 bolts that hold the T-case on to figure it out. My vote, after reading how it happened, is that the splines stripped on the wimpy T-4 transmisson. The shift rails and forks on the Dana 300 are pretty stout, so if it's not the T-case linkage, the tranny is probably it.

Once you have the T-case out, there will be no doubt once you start troubleshooting.

ALSO: 1st posts in Tech are cool, but don't forget to stop in the intro thread too.

[rbunch4468]

perfect! just looking for some reassurance for next steps...Sometimes I have a tendancy to 'over do it'. What is an intro thread? Didn't mean to bypass normal protocol. I'll pull the T-case and report back.

thanks...

[ZAEDOCK]

Nah dude, there's no protocol or anything. It's just nice to know a little about the people who visit.

Are you interested in joining a club? There are plenty of benefits.

[DOUG]

If you find the tranny is junk, I've got a T-5 from my 82 CJ I'll sell you.

[Frank]

Doug : You holdin out on me ? Shoot me a pm on your other 8 - $$$$ ? FjR68

[rbunch4468]

thx...

Currently out of town on business. My first chance to dive into this will probably be Saturday. Sounds kinda wet for Boston weather over the weekend, though...This is a driveway project. No garage. Oh, well.

I'll post after I pull it apart.

[Frank]

You are sure that the linkage is hooked up and working ? On the 300 , there are two (2) shift rails , Make sure as you go through the pattern that they move one at a time but that both move . If they move its probably in the tranny. FjR68

[rbunch4468]

As in most things, one project leads to three more. I got sidetracked this morning to have tires mounted for the wife's MG. Only got the cross member and drive shafts off on the CJ. Still going to pull the T-Case this afternoon. One question so far, though. The front and rear output shafts of the T-Case spin freely, independently, by hand no matter what position the T-Case shifter is in. Is there a differential type effect, or have I already found my problem? The shift rails look like they are both moving (one at a time by shifter position).

Lot of fluid leaks from T-Case judging by the sludge built up inside the cross member. At the very least I want to put in new seals.

More later today...The plan is to pull it, degrease it, and bench test.


Rick

[rbunch4468]

Okay...good news is that I definately found the problem...bad news is the problem is sitting on my kitchen table. The complete output shaft of the T-4 tranny sheared off. Good news is...I have a theory of what caused it...bad news is that the T-Case linkage needs to be rebuilt. The rubber bushing that keeps the fork aligned where it should slide is rotted. Good news is...the bushing should be an easy (relatively) fix. Bad news is...I think it allowed the T-Case to be put in a 'locked' state of front axle in one range and the rear in another. When the transmission tried to drive the T-Case in this state, it sheared off the output shaft clean. Good new is ...Doug has posted the availability of what could be my new transmission at a fair rate...bad news is I won't be back on the road this weekend.

Thanks for the support on this forum...Doug, PM me with your availability this weekend. I'm just down the road in Reading.

Cheers,

Rick

[ZAEDOCK]

Boom.

Good find.

[nostaw]

Ouch... Well, that sucks!

JW