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Old 07-25-2017, 10:35 AM   #1
Zackaddict
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Default Transfer case popping out of 2-hi

Hey guys. Now that my '67 scout 800 is running well I should probably address my transfer case.

I think it's a d20(?) I'm not sure. I have a four speed manual with a 196 engine. Dana 44 in rear and 27(?) in front.

So seeming randomly while cruising in fourth gear my transfer case will pop out of 2-hi. It never pops out of lo. And I can't really get it into 4-hi. 4-hi barely seats and just pops out almost instantly.

Currently I have the stick bungee'd to the seat to keep it in 2-hi. But it will still pop out and grind until I push the clutch in.

I've searched through the forum and found a few threads but none really went into to much depth/ never updated on a solution.

I have the service manual, and it says it might be bent forks,a bad spring or bearings.

Has anyone experienced something similar? What did you do?
I want to drain the trans oil and refill it. Not sure if that would help.
Can I just use 90 weight gear oil?

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Underside of the transfer case
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"Margie" 1967 scout 800 with 196 four banger
"Wilma" 1979 jeep cj5
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Old 07-25-2017, 12:10 PM   #2
Scoutboy74
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Default Re: Transfer case popping out of 2-hi

I'll get right to the point. That unit needs to come down for a rebuild. I don't really see any bandaid approach having a lasting, positive effect for you. That includes a fluid change. And when it comes to fluid, what you want to put in there is SAE 90wt GL-1 mineral oil, also known in some circles as "tractor oil". A suitable substitute if you can't find the above, is single viscosity or straight 50wt racing motor oil. You should not use 80-90wt GL-5 gear oil in the t-case. Save that for the axle diffs.
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Old 07-25-2017, 12:47 PM   #3
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Default Re: Transfer case popping out of 2-hi

Hey scoutboy,

Alright. Is this the tc-145?

Should I pre-order some parts? What bearings/springs should I get?

How difficult/ long do you think it would take to drop the transfer case? Book says to unhook both axles and just unbolt the bolts holding it in. Any idea how many bolts? And pro-tips for dropping it?

I can try and keep this thread updated with my progress / steps in taking.
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Old 07-25-2017, 01:08 PM   #4
Scoutboy74
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Default Re: Transfer case popping out of 2-hi

Its a Dana 20.
Getting a master kit like this...
http://www.ihpartsamerica.com/store/...20-OH-KIT.html
is a far better way to go than sourcing individual giblets here and there. It isn't difficult to remove. It weighs about 70 pounds, so if you're robust enough, you can bench press the thing. If you have a transmission jack, those work really well, but not a necessity. A helper can be employed to slow the decent from above with a long arm or a rope around the shift lever. Both prop shafts come loose at the output flanges. You need a secondary jack or some blocks to support the engine/trans as those items are supported by their union to the t-case and its rest on the cross member. With the t-case out, that support goes bye bye. I'd drain the gear oil out before you drop the case, too.
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Favorite hobby...Driving Salma Hayek in my Scout

Coal Trickle - '99 Dodge Ram 2500 Q-Cab SWB 4x4 - 5.9L 24V CTD/NV4500
Hooty - '74 SII - 392/TF727/D20/3.73 D44's/Spartan FA/Krac-lok RA/RC 4" SUA/34x10.5 TSLs/33g Fuel/HFT 8k winch
Mongo - '71 1210 Std Cab 2WD - 345/TF727/RA17 D60 4.10 Trac-lok - "Mongo love candy! Duh, huh, huh!"
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Old 07-25-2017, 01:14 PM   #5
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Default Re: Transfer case popping out of 2-hi

Thanks for the link. Yeah the book doesn't say anything about supporting the tranny.

Should I drain the tranny oil to? Same mineral oil? How much oil roughly do you think I would need for both?
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Old 07-25-2017, 07:49 PM   #6
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Default Re: Transfer case popping out of 2-hi

Might as well drain the trans oil too and refill with same juice as t-case. Your manual should list fluid capacities. It isn't a huge amount. Get a gallon jug of the stuff and one of those el cheapo fluid transfer hand pumps that screws onto the jug where the cap would go. That should be enough to fill both boxes.
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Favorite hobby...Driving Salma Hayek in my Scout

Coal Trickle - '99 Dodge Ram 2500 Q-Cab SWB 4x4 - 5.9L 24V CTD/NV4500
Hooty - '74 SII - 392/TF727/D20/3.73 D44's/Spartan FA/Krac-lok RA/RC 4" SUA/34x10.5 TSLs/33g Fuel/HFT 8k winch
Mongo - '71 1210 Std Cab 2WD - 345/TF727/RA17 D60 4.10 Trac-lok - "Mongo love candy! Duh, huh, huh!"
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