I have a newly rebuilt engine with 5000 miles on it and a new clutch/throwout bearing as well. I was driving today on a snowy road in 4H with the hubs locked. I hit 4th gear and the engine was lagging (it needs higher rpms in 4x4) and all of a sudden I accelerated in 3rd and it was like I was in neutral. I pulled over and tried to put it in 2H or 4L and the thing wouldn't budge. I went to get it towed and they needed a flatbed because it was stuck in 4x4 even WITH the hubs in free. It will go through all of the gears now with the clutch out and it is like its in neutral. HELP!! What could be the problem(s)?

 

Make the sure the slave cylinder is actuating the clutch fork.

 

Sounds like the clutch is slipping.

 

or the release fork popped loose and is holding the pressure plate open.

 

The cylinder is still working, it is still pushing the release fork unless something popped inside the bell housing. I still don't understand how it is locked in 4H with the hubs on free?

 

the xfer case lever won't move at all?

 

Because the transfer case is still in 4wd...I'm assuming? This would mean the front driveline/differential is still engaged......just the hubs aren't locked in.

 

Good question.

 

that sucks.. i guess you could try draining some oils and seeing of any metal comes out.. drain it into a clean container that way you can reuse it if no metal and still decent. i know your frustration, on my old 85 i replaced my clutch, flywheel, slave and master cyl then 2 days later on the way to work i gernaded 2nd gear and totaly wasted the tranny. so i forked out the money and got a nice HD rebilt trans and had the transfer case gone through and about 3 months later just before my summer vacation trip to the dunes i rolled it and totaled the truck. i guess another thing you could try is mabe drop the front and rear drive line and try turning the flanges on the diffs and and tranny.. that will help rule out or give you a possible idea.

 

This whole thing sounds strange and the only thing that makes sense, at the moment, is that something bound up and broke. There seems to be two separate problems here: clutch not engaging and the driveline is bound.
The two could be related, and if so, I'm thinking it's not gonna be cheap: possibly something in the transfer case broke, locking up the case and breaking something in the transmission (input shaft maybe?).
If the wheels come off the ground, it might be possible to get the hubs unlocked (if they actually are). If they are unlocked and the rear won't spin, then it is sounding like something broke, to me at least.

 

Yes, the transfer case lever will not move at all. I would also assume that something busted in the transfer case, but when the tow truck picked it up and tried dragging it (with the front tires down) the rear tires were turning as well so he couldn't tow it (we had to get a flatbed), even WITH to hubs turned to free.

 

I also recently changed the front and rear diff. fluids, as well as checked the tranny and xfer case fluids. I also recently did a rotor and front bearing job, so maybe I screwed something up when I put the hub back together. However, I still don't see how the clutch could not be engaging.

 

Have you tried shifting the transfer case with the vehicle atleast rolling?

Can you hear the hubs lock/unlock when you turn them? Should hear a little "click".

 

dumb question, and not to be toe-stepping...
but, are the hubs manual or automatic?
if they're automatic, what about rolling the truck backwards?

 

Pull the transfer case shifter off and have a look inside. Might be the end of the shifter popped out of the shift forks and is stuck in no man's land. I find in 4H, you should have both gates in the rails lined up and oriented towards the front. Then stab the end of the shifter into those two gates.

 

I just finished pulling off the shifter plate. The forks were misaligned! I aligned them and started it up to see if she would want to roll and she did! The only question now is what caused this?? Is this common or a symptom of another problem? Maybe just lack of use (this truck had been sitting for a while before I bought it)?

 

Hahaha..........that was my next question. No, really. It was. That's happened to folks when they've pulled the shifters/reinstalled after a clutch job.


Glad you found the problem, though.

 

damned... I hate not being part of the solution.

j/k. I'd rather not be part of the solution... or the problem.

 

Part of the solution = you are now a pickle.

Part of the problem = you are now leaving a sour taste in the mouth.

Pickles are sour. Get used to it, briney.....hehe.

 

Swallow... I did ask first if the shift lever was stuck.
But I will give it all to 4Crawler.