4 Wheel Drive Engagement

RockinRam96

RockinRam96

Active member
Joined
Sep 15, 2011
Messages
2,702
Gentlemen,

I have a 2000 1 ton, 6-speed, four wheel drive - I am having trouble with the transfer case staying in gear. Over the summer my vaccume actuator failed so I replaced it with the cable actuator set up. I can engage the four wheel fine and still shifts into gear just fine. My problem is that the transfer case likes to jump out of gear easily.

Did I miss somthing disconnecting my vaccum lines? Or do I have to adjust the linkage to the shifter handle?

Any help is greatly appreciated. Thanks.
 
Did you remove the switch from the T case itself, or just unplug the vac lines? As best I remember, the switch on the case has a ball and plunger that could be helping to hold the case in whichever range you select.

Mine started jumping into 4 lo on it's own, wound up being the shift fork bushings were worn to nothing allowing it to hold pressure on the slide assembly.
 
I just disconnected the vac lines and moved them to a safe spot. Prior to installing the cable engagement it would hold and lock into gear.

So what have I got to take out and put in place to make this work properly? This was my next move just wasn't sure how to tackle it.

Thanks!
 
Is the cad kicking out or the t-case? I guess what I'm getting at, is the cable set correctly? I just rebuilt one today that the splines on the center shaft were worn to a point and it would kick out under load. BTW the 4wd light on the dash is turned on and off by a switch on the cad.
 
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How many miles on the t case? I wound up rebuilding mine for peace of mind.
 
307diesel said:
Is the cad kicking out or the t-case? I guess what I'm getting at, is the cable set correctly? I just rebuilt one today that the splines on the center shaft were worn to a point and it would kick out under load. BTW the 4wd light on the dash is turned on and off by a switch on the cad.
Click to expand...

The transfer case is popping out of gear, not the CAD. Yeah I must have wired mine wrong and the light doesn't come on. But no big deal I know the feel of the cable actuator to lock it in.
 
Billysgoat said:
How many miles on the t case? I wound up rebuilding mine for peace of mind.
Click to expand...

There is 212,000 miles on the t-case. Before I installed the cable CAD actuator. It would lock and hold into gear.

If you don't mind what did it cost you to rebuild the t-case? Are you able to get a complete rebuild kit or do you have to piece it together?
 
I don't mind telling it was around $300, that was in 04 I think and yes, you can get a complete kit. Before you order, get under the truck and look at the tag on the T case to make sure you get the right kit. I bought mine through Quad 4x4, found it cheaper elsewhere, but not with as good of quality bearings etc.

One thing you might try doing first though, yank the front driveshaft and see how the case acts, with it starting this immediately after replacing the CAD it makes me wonder if you might not have something else going on. I am not a drivetrain expert by any means, but it does sound strange.
 
Cool. I may have to look into doing this, this spring. I am plowing with the truck currently and it is a pain in the a$$ when I am pushing snow, hit a bump and it pops out of gear. I don't move any more after that.

What do I have to properly eliminate the vacuum lines coming from the transfer case? I am thinking (hoping) this may be part of my problem.
 
You might want to adjust on the shifter rod first, it's worth a shot. I am assuming that it is popping out of 4 low into neutral?
 
I was going to look at the shifter rod as soon as we got a brake from the snow.

No it is popping out if 4 wheel high into 2 wheel drive. My **** pattern is 2 low against the dash-neutral-2 high-4 high.
 
Ok, you said the truck stops moving, I'm thinking it goes into neutral from 4 lo. We don't plow snow here so I have no clue about it LOL

I would still look at the shifter rod, it might not be moving far enough to engage fully.
 
Ha ha. Yeah, you probably dont see a lot of snow in Mississippi do ya?! When your pushing an 800 lb steel plow and a 4 ft high wet pile of snow an you loose 4 wheel drive. You tend to stop in a hurry.

I'll check out the linkage as soon as the snow clears for a minute and I get the truck cleaned off. Thanks, man.
 
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