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Gen 4 Transfer Case false neutral

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11 Jun 2025 12:27 #260867 by 300bhpton
Not sure I can be of any real help.

However, not long after getting my Jimny it started jumping out of low. It would do it under load, such as when engine braking or with power on, which could be quite worrying off road.

Eventually the dealer replaced the transfer box under warranty. It is all in my build thread and in some YouTube videos. A number of people have messaged me on YouTube and here over the years saying they have had the same issue.

With the new transfer box it has been fine, although I would say the lever is very sensitive, it only takes a small bit of pressure for it to be knocked out of low. I have an aftermarket tray/cup holder that fits next to the lever and between the handbrake, this can sometimes be enough to make it jump out of low. But without the tray there it never has jumped out again. I didn't have this tray when the original box was a problem.

As for mechanical or electrical. I honestly don't know, forums seem to claim both, although the action and weight of the lever I can't see it being a purely electrical setup, it certainly feels like it moves something. And if it was just an electric switch, it'd have only on/off or engaged/disengaged. Which wouldn't tally with it ending up in a neutral position with no drive.

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11 Jun 2025 12:50 #260868 by DrRobin
Thanks 300bhp, that is very helpful.

The lever is definitely mechanical and your experience with the first TC sounds like a more extreme version of mine.

You seem to broadly agree with others, the lever needs to be positively push all the way back, if not it can slip forwards slightly and let the TC come out of low.

I have an off-road session this weekend, I am going to try several changes between high and low noting how I do it each time to see if there is something more likely to cause the problem.

2020 blue SZ5 (one of the last to be registered in the UK)
Ex 2011 Blue Jimny SZ4
Northumberland Jimny Blog

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11 Jun 2025 12:59 #260869 by DrRobin

2020 blue SZ5 (one of the last to be registered in the UK)
Ex 2011 Blue Jimny SZ4
Northumberland Jimny Blog

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11 Jun 2025 23:49 #260874 by Gadget
I've had it happen a couple of times, but since learning to give the transfer lever a really good yank back into low it hasn't happened again. 
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12 Jun 2025 13:27 #260878 by DrRobin
Thanks Gadget, looks like there is nothing different to my TC, so I will just have to learn to give the lever a good old shove.

2020 blue SZ5 (one of the last to be registered in the UK)
Ex 2011 Blue Jimny SZ4
Northumberland Jimny Blog

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