New defender project, transfer box problem.

[dantips]

I've just bought my first defender, a 1994 90, the first and most worrying problem is I can only find low box.

The guy I got it off says the selector is fitted wrong, could this be right or is it likely to be a bigger problem?

Thanks for any help

Dan

[kiwi_110]

He could be right. Fitted wrong or bent/damaged/disconnected in some way. Start with that assumption because it's the least effort to check. You can see the hi/lo selector shaft where it goes into the transfer case if you take out the centre seat or cubbybox and remove the inspection panel. The selector arm moves forward for Hi ratio, to the rear for Low. If you have to, you can disconnect the linkage from the Hi/Lo shifter at the T/C end and force the selector into Hi. You may need to rock the vehicle while selecting.

Ray.

[dantips]

I'm going to have a look this weekend, thanks for the advice.

[kiwi_110]

Here's a pic of what you're going to be looking at. This LT-230 T/Case is on my workbench but the pic is from above and the rear which is what you'll be looking at when you're trying to view it through the inspection hatch. The lever my finger is pointing at is the Hi/Lo selector shaft input to the T/Case. It will be in the right side of the transmission tunnel and down about level with the drivers floor pan. If it is connected properly, an operating rod will run from it horizontally to the Hi/Lo shifter gubbins on top of the gearbox. You should be able to see if that selector moves when you try the Hi/Lo shifter. If you have to, remove the clevis pin that attaches the operating rod at this point and try to move the selector directly. Pushing it toward the front engages hi ratio. The threaded stub you can see sticking up behind the bit of black wire that's in the way in the pic is the Diff Lock selector but you're unlikely to see that from your vantage point. It should also be linked by rods and levers to the Hi/Lo shifter gubbins.

[dantips]

I've had a quick look this evening, I tried taking the pin out but it hits the gearbox.

It seems as if the lever in the picture isn't getting pushed far enough backwards, how would I rectify that?

Do I need th take it off and rotate it forward?

Thanks again for the help.

[kiwi_110]

Dan, it may not fully engage without you trying to move the truck a bit. I usually select 1st or reverse and work the the clutch pedal in and out a bit to rock the truck while trying to change range. If it really won' travel enough to fully select the ratio you're after, the operating rod is threaded and can be adjusted for length to increase or decrease the "throw" as required. I'm afraid that to do that, you'll have to remove the tunnel panel. Not hard, but fidgety... It's a pity you can't get that clevis pin out. If you could get that rod disconnected, then you can find out for sure if you can engage both ratios prooving your T/Case innards are OK, in which case it will definately be the linkages.

Keep plugging away and you'll nail it.

Ray.