Question about 1986 Suzuki Samurai

1 Answer

Transfer gear case shift jammed

The transfer gear case lever is jammed. It will not go into 2wd or 4wd. My Samurai is stuck in neutral. Shifting transmission into 1st, 2nd, 3rd, or 4th has no effect. Is there a way to unjam it or is something broken?

Posted by on

  • Anonymous Mar 13, 2014

    transfer case won't go in














    stuck in gear

  • Keith Mittan
    Keith Mittan Jun 10, 2016

    make sure your wheels are in the unlocked position

×

1 Answer

  • Level 2:

    An expert who has achieved level 2 by getting 100 points

    MVP:

    An expert that got 5 achievements.

    Novelist:

    An expert who has written 50 answers of more than 400 characters.

    Governor:

    An expert whose answer got voted for 20 times.

  • Expert
  • 166 Answers

There are four probable causes when the gear is stuck in one position, and they are precisely explained in this handy diagnostic article that I know will help narrow down the culprit of your difficulty:
http://yourhandymanzone.com/Your_Handyman_Zone_How_To_Pages_Vehicle_Car_Zone_Cars_Trucks_Vans_Transmission_System_Stuck_In_One_Gear.htm

Good luck!
Brad

Posted on May 26, 2009

1 Suggested Answer

6ya6ya
  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

Hi,
a 6ya expert can help you resolve that issue over the phone in a minute or two.
best thing about this new service is that you are never placed on hold and get to talk to real repairmen in the US.
the service is completely free and covers almost anything you can think of (from cars to computers, handyman, and even drones).
click here to download the app (for users in the US for now) and get all the help you need.
goodluck!

Posted on Jan 02, 2017

Add Your Answer

Uploading: 0%

my-video-file.mp4

Complete. Click "Add" to insert your video. Add

×

Loading...
Loading...

Related Questions:

1 Answer

2002 ford ranger - Where is the 4x4 actuator located


On the transfer case
Transfer Case - Electronic Shift
The four-wheel drive electronic shift-on-the-fly feature electrically shifts the vehicle transfer case between 2WD, 4WD HIGH, and 4WD LOW. The system mode is selected by the operator through the mode select switch (MSS) on the instrument panel. The operator is informed which mode the system is in by two instrument cluster indicators: one for 4WD HIGH which appears as 4WD, and one for 4WD LOW, which appears as 4WD LOW. Shifts into 4WD HIGH can be made at any speed. When shifting into 4WD HIGH with the vehicle stationary, tooth blockage may occur preventing shift completion. When the vehicle is driven above 8 km/h (5 mph) the shift will complete. When shifting in or out of 4WD LOW, the four-wheel drive (4WD) control module requires that the vehicle speed be less than 5 km/h (3 mph), the brake pedal be applied, and the transmission be in NEUTRAL (automatic transmission) or the clutch pedal be depressed (manual transmission).
The gearmotor encoder assembly is mounted externally on the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the 4WD HIGH, 4WD LOW, and 2WD range positions.
The four-wheel drive (4WD) control module controls the gearmotor encoder assembly that shifts between 4WD HIGH, 4WD LOW, and 2WD modes.

Mar 17, 2017 | Ford Cars & Trucks

2 Answers

I have a 93 jeep Cherokee, it will move in 4wh and in 4wl but will not go back into 2wd?


Hello guy
try posting what 4wd system you have,? first.
command trac or select track, (the latter is full time)
part time or the full time system,
we cant guess it....
read the operators guide first, if a part time system only
as i suspect, stop driving on dry pavement.
it's only for ice, or dirt. part time. part time is not a full time system.
Command-Trac
shifting to 4wd on dry (means no ice) pavement causes, drive line wind up! and the gears to lockup. (see steering get tight in turns?> and is dangerous to drive it like this , you, me and the box)
posted here 100s of times.

http://www.rubicon-trail.com/4WD101/driveline-bind.html


the non grand Cherokee. early

had these choices
  • 1987-2001: New Process NP231 Command-Trac, part-time only, 2.72:1 ratio with low range
NP231 has the following settings: 2HI, 4HI, N, 4LO
  • 1987-2001: New Process NP242 Selec-Trac, full-time or part-time, 2.72:1 ratio with low range
NP242 has the following settings: 2HI, 4 full-time, 4 part-time, N, 4LO


as you can see you need to first know, what NP box you have or
photo your shift lever for 4wd, an post it and we tell you.

more facts, on select trac. (totally unlike command trac)
Selec-Trac locking hub is used on 4WD Cherokee. Selec-Trac
utilizes a non-disconnect front axle. Engagement of 2WD or 4WD is
accomplished at transfer case by means of mechanical shift linkage.
System allows full or part time 4WD. Selec-Trac can be shifted into
2WD or 4WD modes from inside the vehicle at any speed.
unquote
next from the service manual,
4WD TO 2WD
1) Place mode select switch in 2WD position. Transfer case
should shift to 2WD and not allow shifting into 4WD or LO range. Axle
should shift after transfer case shifts.
2) To determine if front axle has completed a shift out of
4WD into 2WD, position mode select switch back to 4WD position while
operating vehicle at slow speed. If vehicle shifts into 2WD, axle will
ratchet. If shift is not completed, transfer case will shift into 4WD
and hissing sound will come from mode select switch.
end quote.

if unsure read the FSM book its free.
shows you both systems and how to diagnose it.

in the box, click Cherokee,,then click 1993, and behold.
the real deal.

http://www.morris4x4center.com/knowledge-base/index.htm?utm_source=cj#service

4e7ebed4-9c81-4927-b26e-02808a82acff.jpg

May 10, 2016 | Jeep Cars & Trucks

1 Answer

How do I turn 4wd on?


    • 1 Start your Dodge truck's engine.
    • 2 Turn the electronic transfer case from "2WD" to "4WD Lock" to engage the high range 4WD, if the dodge truck is equipped with an electronic transfer case; otherwise, shift the transfer case lever from "2H" to "4H." The electronic transfer case is located on the instrument panel and is marked with "2WD," "4WD Lock" and 4WD Low." The lever-equipped transfer case is located to the right of your leg and is marked with "2H," "4H" and "4L."
    • 3 Shift the transmission into "Neutral" while the vehicle is either stopped or rolling at 2 to 3 mph to begin engaging in the low range 4WD. Turn the electronic transfer case to "4WD Low," if the Dodge truck is equipped with an electronic transfer case; otherwise, shift the transfer case lever from "2H" or "4H" to "4L."
    Tips & Warnings
    • Indicator lights will come on and alert you that your vehicle is in either the high or low range of 4WD.
    • Do not engage in the low range of 4WD drive if the transmission is in gear; you must shift to "Neutral" first.
    • Many Dodge trucks allow you to shift from 2-wheel drive to the high range of 4WD at up to 55 mph--consult your truck's manual to ensure that this is possible. Do not exceed 55 mph while engaged in the high range of 4WD. Do not exceed 25 mph while engaged in the low range of 4WD.
    • Do not engage in 4WD unless you are on slipper or rocky roads.

Sep 02, 2011 | 2005 Dodge Dakota

1 Answer

2003 F-150 regular cab automatic transmission and the 4WD will not engage.


Operationally vacuum shifts the front axle between 2WD and 4WD mode. The GEM ( Generic Electronics Module ) applies ground to the solenoid needed for the mode selected on the switch ( for ESOF ) or when the transfer case shift lever is moved ( MSOF ).The contact plates in the transfer case signal the GEM that the transfer case is engaged, and the Vacuum solenoids need to be activated ( either 2WD to 4WD or 4WD to 2WD ).


Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc )
Key on, engage 4x4 and try to turn the front drive shaft.
- If it turns it is a problem with the transfer case.
- If it doesn't it is a front axle engagement problem.

- If the front drive shaft does not turn :
•With the truck running ( with front wheel back on the ground ), switch from 2WD to 4WD and back again, the vacuum shift motor should move the lever on the front axle.
{ picture of shift motor }
-- If the vacuum shift motor does not move:
•Check for vacuum on the lines while shifting between modes. Pink vacuum line is 2WD mode, Light Blue vacuum line is 4WD.
•Check the fuses for the 4WD system and the solenoids.
•Check the vacuum lines from the vacuum shift motor to the solenoids on the firewall.
•Check the vacuum lines from the solenoids to the vacuum reservoir box behind the battery.
•Check the vacuum reservoir box for cracks.
•Typical solution is the vacuum lines ( to the solenoids or to the vacuum shift motor ) are cracked or the vacuum shift motor has a cracked diaphragm and has water in it.
•Could be the shift plate contacts in the transfer case are corroded / not making good contact, and not activating the solenoids.
sscullys_111.jpg

- If the front drive shaft turns:
•For ESOF system
-- Check the fuses for the transfer case, engine compartment fuse panel, 17 & Cab fuse panel fuses 13 and 23 ( verify with owners manual, 97-97 & 99-03 MY can be slightly different on some items ).
-- Try hitting the transfer case with a dead blow hammer ( do not use a metal hammer, it can damage the transfer case ) to see if the transfer case shift motor is hung up .
-- Check the transfer case connector, to make sure the connector pins are clean and making good contact.
•For MSOF systems
-- Check that the shift linkage on the transfer case is moving when the lever is moved from 2W to 4H and 4L.

Jan 10, 2011 | 2003 Ford F150 Regular Cab

1 Answer

Transfer case removal


Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide
Transfer Case Assembly - REMOVAL & INSTALLATION

Samurai Models
Even the 2WD Samurai uses a transfer case. Rather than use a straight line driveshaft from the transmission to the differential, the Samurai leaves the transfer case in place and replaces its internal working with a simple offset gear mechanism, thus keeping 2 of the 3 driveshafts used in the 4WD vehicle.
  1. On 4WD vehicles, remove the transfer case shift lever.
  2. Raise and support the vehicle safely.
  3. Drain the oil from the transfer case.
  4. Matchmark and remove the driveshafts from the transfer case assembly. Not all of the driveshafts need to be completely removed from the vehicle, just unbolted from the case flanges. In most cases, the shaft or shafts on one side of the transfer case can be repositioned and supported out of the way.
  5. Support the transfer case using a suitable transmission jack.
  6. Disconnect the speedometer cable from the transfer case.
  7. On 4WD vehicles, disconnect the 4WD switch lead wire at the coupler.
  8. Remove the three mounting bolts and/or nuts securing the transfer case to the chassis, as applicable.
  9. Carefully lower the transfer case from the vehicle.
To install:
  1. Position and install the transfer case. Tighten the mounting bolts to 159-248 inch lbs. (18-28 Nm) and/or the mounting nuts to 19-25 ft. lbs. (25-34 Nm).
  2. On 4WD vehicles, connect the 4WD switch lead wire at the coupler.
  3. Connect the speedometer cable to the transfer case.
  4. Properly refill the transfer case with an approved type of gear oil.
  5. Align and install the driveshafts to the transfer case.
  6. On 4WD vehicles, install the transfer case shift lever.
  7. Remove the jackstands and carefully lower the vehicle.
Sidekick, Tracker, Sidekick Sport and X-90 Models
On these models the transfer case is bolted to the transmission and takes the place of the 2WD transmission's extension housing. Therefore, transfer case is removed or installed as part of the transmission assembly.

Hope this help (remember rated this and comment).

Mar 21, 2010 | 1993 Geo Tracker

2 Answers

4wd does not work


Electronic Shift On the Fly (ESOF) Operation
The ESOF system is an electronic shift 4x4 system that allows the operator to choose between two different 4x4 modes as well as 2-wheel drive. The operator can switch between 2WD and 4WD HIGH mode at speed. To engage or disengage LOW Range, the vehicle speed must be less than 5 kph, the brake depressed, and the transmission must be in NEUTRAL.

The transfer case is equipped with an electromagnetic clutch which is located inside the case. This clutch is used to spin up the front drive-line when shifting from 2WD to 4x4 High mode at speed. When the control switch on the instrument panel is turned, the generic electronic module (GEM) recognizes that a shift has been requested and activates the electromagnetic clutch and the relays which power the transfer case shift motor. When the shift motor reaches the desired position as determined by the contact plate position inputs to the GEM, power to the shift relays and motors will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the main-shaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.

Shift Between 2WD and 4x4 HIGH:
Shifts between 2WD and 4x4 HIGH can be made at speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes.

Feature Inputs:
*4WD Mode Switch (Various resistances).
*Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open).

Feature Outputs:
*4x4 Shift Motor Relay Outputs
*Transfer Case Clutch Relay (grounded when relay is on, open circuit when relay is off).
*4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated).
*Cluster Indicators (ground when activated, open circuit when deactivated).

Shifting Into/Out of 4WD LOW:
When shifting into or out of 4WD LOW, the GEM requires that the vehicle speed be less than 5 kph, the brake is applied, and the transmission is in NEUTRAL.

Feature Inputs:
*4WD Mode Switch (Various resistances).
*Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open).
*VSS Sensor (Sinusoid Signal: 0.7V-20V, 2.2 Hz/mph).
Brake Input (battery voltage when brake is depress, open circuit when not activated).
*Transmission Range Sensor (grounded when transmission is in NEUTRAL, open circuit otherwise).
8Start/Clutch Depressed Input

Feature Outputs:
*4x4 Shift Motor Relay Outputs
*4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated).
*Cluster Indicators (grounded when activated, open circuit when deactivated).

4WD Mode Switch
A rotary switch allows the vehicle operator to choose between 2WD, 4WD HIGH, and 4WD LOW modes of 4x4 operation.

GEM Module
The Generic Electronic Module (GEM) controls the operation of the 4x4 system

Vehicle Speed Sensor
The vehicle speed sensor (VSS), mounted in the rear of the transfer case, informs the GEM of the vehicle speed.

Transfer Case Shift Motor Sense Plates

The shift motor sense plate, an integral part of the electric shift motor, informs the GEM to the positions of the transfer case

Transmission Range Sensor
Located on the left side of the transmission, this sensor informs the GEM when the transmission is in the NEUTRAL position.

Electric Shift Motor
The electric shift motor, mounted externally at the rear of the transfer case, drives a rotary cam which moves the mode fork and range fork within the transfer case to select between the 2WD, 4WD HIGH, and 4WD LOW positions.

4x4/4x2 Vacuum Solenoids
These two solenoids are attached to the upper RH side of the engine compartment dash, and alternately route vacuum to the vacuum motor which engages/disengages the center axle disconnect collar in the front axle assembly.

4x4 Shift Motor Relay
A module containing two relays which under the control of the GEM, shift the transfer case shift motor between the 2WD, 4WD HIGH, and 4WD LOW modes.

Transfer Case Clutch Relay
An electromechanical relay is used to activate the transfer case clutch within the transfer case.

Good luck and hope this helps,but start with the simple and check the fuses and wire harness. Both white/light blue stripe wires should have 12V in run. The GEM will ground the left side (closest to engine) solenoid to disengage the front axle. It will ground the the right side solenoid (closest to fender) to engage the front axle. If the GEM doesn't see Neutral it will not let the truck come out of 4Lo. If the GEM had water leaking on it it may well be the root of the problem. The shift motor only has power when the GEM sends it a signal to move the shift lever. Once the shift is completed the motor shuts off. There are 2 wires that control the shift motor. A yellow and an orange. The GEM alternates between 12v and Ground to these wires to control which way the motor turns. The GEM uses the transfer case shift relay module to control the power to the motor. There are contact plates inside the shift motor assembly that indicate the position that the shift lever is in. This is what the GEM used to know what the T-case is doing. Any one of these components can fail.







Jan 10, 2010 | 2002 Ford Explorer

1 Answer

91 trooper stuck in neutral


possible range selection detent switch not working causing to get stuck some times in one range only and wont shift to other range 4wd light in dash just keeps flashing for about 10 seconds then goes to previous state this then can jam up 2wd 4wd lever that you then cannot move.
there are 3 switches 2 on trans/transferr case, 1 on front LH diff axle tube actuator (shift on fly). can cause damge to the electric actuator then on transferr case.
suggest you get a dealer to look at or some one that knows this system. is also vaccum operated on front diff shift on fly unit and there were 2 different systems fitted to these vehicles push button 4wd on dash and lever next to gear lever which i take is yours

May 27, 2009 | 1991 Isuzu Trooper

2 Answers

While shifting from 4x4 to 4x2 the gear lever is jammed at neutral position & jeep is not moving


there are no syncros in the transfer case, that would ease in shifting. i would try putting it in gear with the transmission, this will reposition the gears in the transfer case. then back to park or neutral. now try shifting to 4x2.

Jan 07, 2009 | 1988 Suzuki Samurai

1 Answer

Can't transfer to 4L or neutral mode


Transfer cases can be quirky. I've got a 91 Wrangler, an 86 Cherokee and a 75 Blazer. When I go from 2WD to 4WD, they each have their own personality.

There are a number of things I've learned to persuade a stubborn xfer case to shift.

Try mixing these :
  • Engine running, vehicle not moving
  • Engine off, Shift Xfer case, Restart
  • Tranny in neutral
  • Shift Xfer case 'N', Tranny in gear, Tranny in neutral, Xfer case to 4HI or 4LOW (as long as you feel it register), Tranny in gear, try to move
  • Shift Tranny to Reverse, roll a few yards
  • Lock/Unlock the Hubs
To get back to 2WD:
  • Drive for a few feet in a straight line
  • Unlock the hubs
  • Tranny Neutral
  • Shift xfer case
Let me know how it turns out.
Mike

Jul 27, 2008 | 1991 Jeep Wrangler

Not finding what you are looking for?
Cars & Trucks Logo

924 people viewed this question

Ask a Question

Usually answered in minutes!

Top Suzuki Experts

yadayada
yadayada

Level 3 Expert

75197 Answers

Colin Stickland
Colin Stickland

Level 3 Expert

22095 Answers

Boyet Soriano
Boyet Soriano

Level 2 Expert

293 Answers

Are you a Suzuki Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides

Loading...