Hilux transfer case worries

[Blackened]

G'day
I have a LN46 'lux 4x4, fitted with a 2.2 diesel mated to a 5spd box. The 5spd is about 1985 vintage. When i was out playing n the dirt, mud and up n down the hills today i noticed that when under load the transfer case selector was continualy jumping out of low range and into neutral. This isn't the nicest thing to happen when you're going up some serious inclines and through mud runs. I suppose the question is how do i fix it and how difficult? I'm suspecting that it's probaly wear and i'm mechanically minded. See how we go.
Dave

[Big_Kev]

That box is due for some attention.
The engaging hub will be worn, the shaft will be worn and the low range gear as well.
Lots of dollars needed in those bits alone without replacing the bearings etc. More then likely put a good down payment on a late model.
Someone with a fair bit of experience in transmissions is what is needed if you want to bodgey up the old lux to get some more service from her on the cheap.
But this sort of repair comes with the usual concrete warranty.(As soon as its off the concrete it will expire)
Or a bit of rope tied to the stick will work for a bit.

[Blackened]

G'day
Thanks for the reply reelhard... that's the only kind of work i havent done, internals in the gear box's. She's got a marvellous 514000 on her so no surprises. I dont do a great deal in 4x4 but do love a play now and then. Wonder what a decent 2nd hand box is worth?? although, it's probally not worth it...
Dave

[Big_Kev]

Second hand box would not be worth it unless yours is smashed.
Pull it out and strip it down.
If you are mechanical minded you can do it just get a gregory's manual.
I would say to replace the engaging hub and back grind the teeth on the gear. This may just work and will be a cheap paddy whack even if it doesn't.

[munch]

Hey Blackened, another line of thought for you. A very common prob with loluxes that have a couple of inches of body lift is the low range lever fouling on the body. something to have a look at before you spend big moolah. good luck

[Blackened]

G'day
Thanks munch. The only lift is a 2'' spring lift. This is a "new" problem, hence ruling out any possible problem with the body, but will have a look and check clearances anyway.
Dave

[Fishin_Dan]

My cousin had this problem on his 40 Series the other week... Turned out he had sheared the gearbox mounting bolts, and his gearbox had twisted slightly and was sitting on teh selector.... He'd occassionally drop out of low range into neutral. Might be worth checking... Probably not the case in this situation, but always worth cancelling out :)