[Guest]

Need help with 4:16 x-fer popping out of gear

Guys,

I have a RRO 4.16 xfer case with the 2lo option installed that keeps popping out of gear. when I first installed the xfer everything worked smooth, but then as time went on I noticed that the xfer would pop out of gear under load, recently it has gotten so bad I can't even get down the street without it going. It doesn't pop when i am in 4 lo, but 4high and 2wd it does. ANY input is appreciated!

 

[2542]

Re: Need help with 4:16 x-fer popping out of gear

That is exactly what mine was doing. I could use 4lo but forget about 2hi or 4hi it would just pop out and grind. It ended up being bent shifter forks. They were replaced and it solved the problem.

Koko

 

[wildweasel]

Re: Need help with 4:16 x-fer popping out of gear

also check to make sure the tcase mounts are not tweaked.
They often are and the shifter will contact the body and pop it out.

 

[763]

Re: Need help with 4:16 x-fer popping out of gear

Yeah heres a second on what wildweasle said, if you haven't beefed up your arms yet it is probably that. The stock ones just don't hold up to the bigger gears.
F_T

 

[3693]

Re: Need help with 4:16 x-fer popping out of gear

And here is a third.... Every time I have had a problem with this, it has ended up being bent t-case arms or the bolts that connect the arms to the case were loose.

 

[Sarge]

Re: Need help with 4:16 x-fer popping out of gear

Here's another: the sliding collar that selects between hi and low on the main shaft can get worn . I had to flip mine around and increase the spring tension on the retaining ball to keep it in gear . Need to get a part number and get one ordered . This is the collar that the hi/low shift fork moves between the main cluster....anyone got a drawing and the part number?
Sarge

 

[Guest]

Re: Need help with 4:16 x-fer popping out of gear

Hey guys thanks for all your input. I took the x-fer case out this morning and looked an everything you mentioned. The arms were straight and the mounts were good, so I took the front of the t-case off to get a better look at the "2lo" option that was installed. They took a lot of metal off the fork and to tell you the truth I didn't really like it, so I replaced the fork with one out of the tcase that I am rebuilding with the 4.9 gears- and volia!, nice SOLID shifting and no more pop outs! I think the shifting arm was in backwards as well, but I can't be sure, alls I know is that I am back on the road with no more tcase trouble. I went a step further and filled the tcase up with as much gear oil as I could put in it, and boy, what a difference-no geartrain whine at all! I could even listen to the radio!

Anyway-thanks for the input-all of you!

Now- anyone have an incomplete transfer case that they want to sell me the shifting fork out of??? I'll give you my "2lo" modified one! (j/k about the 2lo fork-I wouldn't give that thing to my worst enemy! but I do need a replacement)

 

[Sarge]

Re: Need help with 4:16 x-fer popping out of gear

Don't be too quick to overfill a tcase , you'll do nothing more than blow seals . If the case is noisy, either replace the bearings or use a bit heavier oil ...
Sarge