Only last week I got the gearbox in my 1986 Sahara re-conditioned to find that it still will not engage low gears when I 4 wheel drive. I have been told by the "Mechanic" that I broke it because I pressed the 4WD button on the dash board. I was just wondering if you can tell me if I have damaged it or if he is talking bull!
Also a users manual for an FJ60 would be a big help, do you know where I could find one of them?
a 6ya Mechanic can help you resolve that issue over the phone in a minute or two.
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Using the shorter gear leaver in the samurai, the gear choices are arranged in a simple U fashion. They are arranged in sequence. At left top, bottom, right middle and right top you have 2 high(2H), 4 hight (4H), neutral(N) and 4 low (4L). 2H- Engages rear wheel drive only. 4H- Engages all wheels in 4X4 mode. N- Disengages all wheels (if you gonna tow your vehicle) 4L- Engages all wheels in 4X4 mode with 50% more torque but you cut your top speed by an equal amount. If you have the OEM gear knob the diagram of the layout of the transfer box should be imprinted. 2 high should be used on dry and mildly wet paved roads. Using 4L or 4H in these conditions may result in damage to your transfer box. You may use 4L or 4H in any other road conditions.
I do think this is a low oil condition and you need to get it addressed now.Low oil will damage the transmission very quickly.The factory trans oil in this car is a light brown and almost the color of motor oil.The oil in an automatic transmission is not just for lubrication, it is also the hydraulic and cooling medium.Low oil means low pressure which means slip which means damage.Have the car towed to a sevice facility.This transmission can cost 4 to 5 thousand to repair.Good luck!
On an 86 you probably still had the hub locks on the outside. You have to get down off the truck and manually turn the hubs to the lock position. The hubs are located in the middle of the wheel. Then Put the 4 wheel drive gear shift to 4 hi or 4 low. At the low level it runs very slowly and very low geared. At 4 hi, it runs normal but the 4 wheel drive engages. When you are not using the 4 wheel drive it is good that you get off the truck and turn the hubs counter clockwise to the off position.
The self locking hubs (or automatic hubs) are actuated by vacuum. The vacuum line is usually on the driver's side of the differential, towards the front of the vehicle on Toys. You might want to check it out and see if it's cracked, broken, or gone.
It sounds like your driveline to the rear wheels is broken. Could be transfer case output shaft to the rear wheels has broken. Try disconnecting the rear drive shaft and see if you can turn it by hand with the transfer case engaged in 2WD. If you can turn it while the Sahara is in gear, the output shaft is no longer connected to the engine for some reason.