AboutDavid Scott Expertise Questions regarding the advisability of different kinds of modifications to Samurai/Sidekick/Tracker or various kinds of off-road usage. I will not attempt to do more than provide links for questions about other Suzukis such as Vitara, Grand Vitara, etc. I may or may not give generalized advice for newer models, but have no experience regarding newer models, and will not attempt to give more than the most generalized answers for questions regarding vehicles later than '93 manufacture. I will however, if possible, provide a link that will help you contact a professional in your region.
Experience I've been a professional mechanic for over thirty five years, live in the center of the Rocky Mountains, and have been active in exploring the old mining/4wd roads for decades. I've specific experience with Samurai modification, because that's my personal vehicle.
Education/Credentials Thirty five years of advanced, intensive classes for experienced professionals only. Manufacturer seminars and training classes averaging four to six weeks per year. I'm now a professional heavy duty fleet mechanic, and no longer deal with issues such as MIL (check engine) lights
Expert: David Scott Date: 2/18/2008 Subject: SJ410 Transfer case stuck in Neutral
Question Hi
I recently changed the oil on my SJ410('84) Transfer case and now it is stuck in N! After draining the old oil, I tried filling it up via a allen key grub screw located about halfway up(a spring was inside which I removed), that was a struggle as the oil kept running back. I then put the the case in N to retry, and it is still there!
I eventually removed the lever and filled the oil from there.
A friend advised about a rubber bush that wears, but there was no such bush, only a metal bush that pushes in and locates on the ball on the bottom of the lever's slot-bolts.
Any ideas?
Thanks
Willem
Answer All my experience is with USA 86 and later, but I'm led to believe they're virtually identical.
The bush that your friend refers to supports the lower portion of the ball at the lower portion of the shift lever. There is also a small bolt with the end machined into a pin that protrudes and guides the ball portion via a slot machined into the ball portion. When worn, they can allow the end of the shifter to jump out of the correct position, and could be the cause of your problem.
Try removing the shift lever, and attempt to move the shift forks. This will usually allow you to get things re-aligned. There is an interlock ball between the two shift fork rails that will only permit one to be moved at a time.
Keep asking questions until we find out what's going on.
On my t-cases, the drain and the fill are identical, and the fill is at the rear, a little less than halfway up the left side.
scotty
