[zorb_rules]

Hey guys I've had a problem with my transfer lever and case in the new car I picked up originally I thought it wasn't going into 2wd so I replaced the bush/o ring (old one was basically green mush) and it still seems like it isn't going into 2wd. whn I put it into 4h or 4l and roll the car I can see the shaft above the transfer case spinning and when I put it into 2wd I can see the one below and infront of the case spinning. Firstly is this what is meant to happen?

Secondly when I start the car and put it into 4h or 4l and go to drive it, it will take off and drive as normal (ive only driven it about 10 meters) however in 2wd nothing seems to happen and its like the car is in neutral.

What am I doing wrong and do you have any suggestions. Sorry if theres an easy answer I have searched but couldn't come up with much. Your help is greatly appreciated.

[zorb_rules]

Hey Guys

I have so far tried the following: replaced shifter seat, refilling the transfer case and greasing the shift forks, and realigning the shift forks as per instructions.

However it still will not shift into 2h, what I have noticed is when I realligned the shift forks as shown in the instructions mine were sitting forming a square but weren't dead center in the bore - more off to the left. Ive also noticed that the car will shift into what seems like 2h but it is down from neutral on the shifter and when in this position the car will not go take off when in gear unlike when it is in 4h and 4l.

Also im getting differing opinions should I be reallinging the shifter when it is in 4h or neutral? I have tried both with no effect.

If anyone has any ideas that would be great. Thanks

[zorb_rules]

Ok guys so I've played with it some more when I go to realign the shift forks and have the transfer lever in 4h if I then align the shift forks from that position I can shift straight into 2H and drive the vehicle. However once I go to shift into 4L or 4H I lose 2H again and can't get it back without repeating the process.

HELP Please I'm so confused.

[tanshi]

your confused? have you read back through what your asking cos i have no idea what your talking about

[zorb_rules]

I'm trying to reallign the shift forks in the transfer box when I reallign them beginning with the stick in 4L I can get the car to run in 2H (when reading the article how to reallign the shift case it says to start with the shifter in 4H) however I couldn't get 2H doing it that way. When I do finally get the case to shift into 2H once I change to one of the other transfer gears (4h or 4l) I lose 2H again.. question is why? Or more to the point is there any ideas why? As above I've done all the obvious (shifter seat replaced, forks greased, oil changed etc)

[tanshi]

are you sure you are shifting the correct rail for what you are trying to do??

[zorb_rules]

well Im hoping so..Im just following the guide from http://www.zukioffroad.com/Tech_Library ... ting.shtml and the corresponding info both on this forum and suzuki talk. Hence the reason I'm asking why or what I should be doing?

[tanshi]

take a pic down the shifter hole and post it up.

when in certain positions the other rail wont shift. specially if your doing something crazy like trying to shift into 2 low by mistake

[zorb_rules]

Heres a photo I just took apparently according to the transfer stick when I removed it this is neutral

Attachment:

IMAG0161.jpg

[tanshi]

that to me looks like it is in 4H, if you move the stick on the right of the picture down(backward) it should be 2H
if you move the left one back ward 1 notch is should be neutral, and one more backward should be 4L

[tanshi]

note if you move the rail into 2H the other rail wont move.

and vice versa if you move the other rail into neutral or 4L the 2H rail wont move

[zorb_rules]

ok so if I move the one on the left backward a notch and reinsert the shifter it should be in neutral is that correct? Sorry about the questions but I've been at this for days using all the tech available but wth no difference. I'm only trying to get it into 2H so I can actually drive it and test it without worrying about damaging the gearbox and difs on ashphalt roads

[tanshi]

thats correct
if you just want 2H move the rail on the right backward all the way, done

[zorb_rules]

Thankyou greatly appreciated..Ill let you know how I go

[want33s]

Do you have a body lift fitted?

Sometimes when a body lift is fitted you need to clearance the shifter holes in the floor.

[zorb_rules]

No Body lift that I can see..Tanshi just too add to your comments I managed to shift it into what I presume is 2H so Thankyou. Only thing is I figured while the stick was out i'd try your method to shift into the other gears which also worked...except for in 4H when in 4H (like in the photo I took) when I try to drive the car its like its in neutral and won't move any ideas?

[tanshi]

ok so.
the right hand rail in your pic has two positions. correct?
the left hand rail has three positions. correct?

with the right hand one all the way backand the left one all the way forward your in 2wd, high range

push the left hand one all the way forward, this is 4wd, high range

now push the right hand one back ward 1 position. this is neutral

push the right hand one forward till it stops. this is low range, 4wd

[zorb_rules]

OK Thanks shall try tomorrow running out of light now and the damn lead light just blew a globe..But yes what you were saying is right (i think) The left one goes forward and backward one notch from the photo that I took and the right one only seems to go forward one notch..one last thing can you rewrite your previous post (sorry to be a pain) but I think you might have written one of the movements wrong as they all seem the same.. or maybe Im just retarded (Highly probable)