We are running a dual case setup with a 470 gear in the back case. The shifter in the back case gets stuck in 4H. The shifter looks like it would be in 4 high but in fact it acts like 2 high. Every time this happens we have to pull the shifter, move the selecting forks forward and reinstall it, then it works again for a little bit. It sounds crazy, but we did try turning the shifter around so that it faces away from me. This resolved the problem for only a short window. Any help would be greatly appreciated. We have been fighting this problem for weeks. Oh also, we have had the case opened everything looks great. The shift forks have been measured and do not need to be trimmed.

 

Might not be your issue and I only have your everyday single case etc etc but that happens alot to me when I am driving on a high traction surface when in 4 LO. I just back up some to unload the gears and it usually resolves the problem. I guess that could be typical of a gear driven case?

 

xxxtreme22r, thank you for your help. We have tried that too. It is really stuck, stuck so much that we have to pull the shifter in order to get it to release.

 

I don't know much about the dual case setups, so I am not much help, but maybe it's some bad seat bushings/seats leading to the linkage binding or maybe just some loose linkage between the two cases? How much play is in the shifter when in gear?

 

Is the shifter jumping out of the shift fork rod?

 

my does this sometimes. It will come out of 4lo to 4hi at a stand still. but wont come out of 4h. just give it a little gas and while your going, jam the shifter up. never fails to get mine unstuck. Hope you figure it out

 

Try and find out what is going on with the end of the shifter as you pull it out of the case. See where the shifter end is in relation to the slots on the two shift rails. Might be yours is popping out of the to aligned slots and that would cause a lack of ability to shift. Do you have the interlock pin in place in the case (it would have to have been removed on purpose)? What I do is line both slots up in 4H (both to the front) and then stab the end of the shifter into those two aligned slots and then put in a bolt or two loosely and try out the shifter to make sure the shift pattern works before bolting it up tight.

 

When i pull the shift tower off the 2 wheel drive shift rod is moved back. You can easily pop it back up with a screw driver. And then if u you put the tower back on it will work fine until it has a load on it. The pin is there and the shift rods have been shaved down. I also replaced the detent springs with heavy duty ones from trail gear. And ones it locks up it is stuck no matter what you do the shifter will not move. Any ideas because I am out of them.

 

So, what exactly is not right then? If the shift rod moves freely with the shifter out, what is preventing it from moving when the shifter is installed? Does it pop out of position? Is it too short to engage the shift rails fully?

 

The 2 wheel shift rod moves back and the shift leaver gets stuck between it and the 4 wheel rod

 

Sounds like either the slots in the shift rails are worn too big or the end of the shifter is worn too small and it is getting stuck or popping out of the gap. If shifter worn, might be able to weld a little metal on the end to build it up (typically it is ~.25" wide and ~.45" long at the end) or pick up a used one at the junkyard. Basically make the end of the shifter bigger than the gap between the shift rail slots.