hi all,

i'm new to the world of 4x4 and Hiluxs. I recently purchased a 1991 mk3 2.4 diesel 4x4 hilux (manual transmission & manual hubs). The previous owner never used it in 4WD mode as he only drove it on the road and had removed the front prop shaft (he said it made the mpg better?). Well as i'm gonna be using it off road i wanted to get the 4WD working again. I put the front prop back on and the ratio selector (transfer case shifter) was stuck in the H2 position. I removed the shifter stick and the levers beneath moved fine (see pics below), but upon putting the shifter back it got stuck again. I suspect it may be the shifter stick itself as the part that engages the levers looks pretty worn. Can anyone confirm from the pictures below if this is how the shifter stick should look? If possible could someone please post a picture of how it should look?

Many thanx

Pete

 

It looks like that shifter stick has been welded and then ground back down. It looks like it may be a little to wide for the slots in the shift rails. It fits fine when both slots are lined up (in 2h) but when the slots in the shifter rail are offset the gap is too narrow for the stick. With the rails offset like in your first or third picture, measure the width of the opening , then compare that with the width at the bottom of the shifter stick.

 

i hope the piece that broke off did not damage the gears in the t-case, and you could be missing the shift rods when you put back on.