4WD to 2WD problem

Paul- is your issue basically that the lever is reluctant to switch back to 2wd having been in four?

If so I have this issue sometimes- I believe it's because some wind up may have occurred. I was advised on here to slowly reverse whilst applying light pressure to the transfer lever until it skips nicely back onto 2wd.

Sometimes mine is fine (when I've been on v slippery mud etc) but other times it plays up and I have to use the method above.

Hope this helps

So the lever is not moving far enough to fully disengage the drive to the front axle. Thinking logically, this could be because the transfer case has moved (you've checked the mounts so probably not), a bent gear lever, something blocking/obstructing the gear lever, or something bent/damaged inside the transfer case.

Someone that knows the innards of a transfer case better will know if there's anything that can be damaged inside. Try taking the gaiter off to check the lever isn't fouling anything where it comes through the body.

Many thanks for the responses so far, I'll try to give a bit more detail but hopefully without creating any confusion.

I can push the lever its full normal travel distance into 2WD no problem and the light goes off. I set off and then suddenly you notice the 4WD light is on and the lever has slipped back into 4WD. Having set off down the road it can do this quickly or you can travel for a bit before it happens.

Even though the lever is put in 2WD I've noticed that car does not actually feel that it has gone into 2WD when driving. I end up having to use a mix of methods to get it to go into 2WD properly. Once it's back in 2WD it will stay there indefinetly with no problem.

I've noticed that it feels that with my hand on the lever, for the lack of a better description, it 'rumbles' it's way back out of the 2WD position.

I have to use 4WD a lot due to where I live. I do at least a couple of miles a day on mud and loose gravel so I don't think wind up is the problem. Plus I've not had a problem for years until the last few months.

You'll need to forgive my ignorance at this point but I need to ask a stupid question. If the vacuum hubs don't disengage from 4WD would this transfer enough 'torque' back to the transfer box to upset its operation?......just an abstract thought.....

Thanks to all

Paul

Vacuum hubs shouldn't affect the lever and transfer box at all. Sounds like a detent (or whatever else holds the lever in position) has packed up Inside the transfer case.

If you decide on a different transfer box I have one for sale cheap

My 2004 does exactly the same when I have transmission wind up and if
I reverse a short distance the lever moves easily and doesn't slip back in