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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
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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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Old 07-26-2017, 04:56 PM   #7
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Default Re: Transfer case popping out of 2-hi

If its a T18 or T19 they hold close to a gallon each. I've found it much easier to just pull the shifter off the top of the tranny and use a funnel to pour the oil in through the shifter hole. Just make sure you don't drop the dowel pin on the side down into the tranny. Also have to pull out the filler plug on the side of the tranny so you can tell when its full, and not over fill it. Transfer case will require the pump. My memory says about 3 pints.
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1975 Scout II healthy 258, Wide T19 , 4:1 D300 3:54s,
1972 Real clean stock Scout II P/S, P/B, 345, T18, 3:73s
1969 Mach I. Balanced ported 351W, 650 double pumper, Super T10, Detroit locker with 4.11s. Lowered with racing springs, bars, Konis etc.
(Don't worry about getting arrested when I drive the Scouts).
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Old 07-27-2017, 05:12 AM   #8
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Default Re: Transfer case popping out of 2-hi

The kit you linked to. Does that include the poppet ball and spring? I can't see them in the picture.
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Old 07-27-2017, 06:21 AM   #9
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Default Re: Transfer case popping out of 2-hi

That's a product question for the vendor. I don't know.
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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 08-02-2017, 10:54 AM   #10
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Default Re: Transfer case popping out of 2-hi

Update

The transmission cover looks like it came off a scout 80? I'm guessing the last owner swapped it out. Well in any case the opening for the transfer case levers was too small and wasn't allowing the levers to engage properly. Cut the cover back a. It and it seems to be fine. Hasn't knocked itself out of gear. I can actually put her in four wheel drive now.

Just have to make everything look pretty now. Oh and new fluids. That should be good
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Old 08-02-2017, 11:12 AM   #11
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Default Re: Transfer case popping out of 2-hi

Side note

Because when I fix one issue another pops up. Which thread category covers clutch issues?
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Old 08-02-2017, 12:30 PM   #12
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Default Re: Transfer case popping out of 2-hi

Ahh it's the little things that get you. Good thing is, it sounds like at the last owner didn't put much wear and tear on the front axle, driveshaft, and half the transfer case. I'm thinking transmission forum for clutch issues.
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1975 Scout II healthy 258, Wide T19 , 4:1 D300 3:54s,
1972 Real clean stock Scout II P/S, P/B, 345, T18, 3:73s
1969 Mach I. Balanced ported 351W, 650 double pumper, Super T10, Detroit locker with 4.11s. Lowered with racing springs, bars, Konis etc.
(Don't worry about getting arrested when I drive the Scouts).
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