poppin out of low

towpainter3

towpainter3

Member
My d20 is wantin to pop out of low range. It seems to do it more under heavy loading and flexing situations , acts fine just cruisin the easy stuff . Any thoughts or suggestions? Motor mounts seem fine, and trans mount is good , havent checked to see if the sticks hittin the body but I think its good , there too. Gonna remove the boots and drive her tomorrow. And theres no problem engaging the hi or low sides either. Or any strange noises.
 
Typical result of the poppet springs having lost tension, the balls May be worn down or "split", and or the bores of the spring/balls are corroded allowing the balls to not engage the shift rods correctly.

Also possible that the corresponding slots in the shift rods have worn significantly.

Or...all the above which indicates rebuild time.

Many folks on the forum have the same issue, most of 'em use a ratchet strap to hold the lever into 4low position when the rig is under strain.

If allowed to continue to jump out of gear under load, the shift fork will eventually "bend" (burn) and will no longer move the sliding gear into index position and hold it in the proper location.
 
Ok seems realistic to me. Nasty and corroded is more likely the problem. Prolly full of mud. Can the rods and such be removed without a full dismantle or am I fubard into tearin her down?
 
If the shift rods need to be replaced, then it's a complete teardown/overhaul.

To service just the poppet balls/springs, once the unit is on the bench, you can remove the "front output shaft bearing cap" after removing the shift lever. That component contains the springs, poppet balls, and the shift "interlock" pills.

Some of the cases use rubber plugs (normally reusable) to seal the holes where the poppet balls/springs are dropped in place, some use thread-in plugs that are re-used. Originally on a Scout II, one of the holes had a switch to turn on the "four wheel drive" or "front axle engaged" light...lots of variations of that setup though.

While the bearing cap assembly is off, the rods should be polished and the seals in the cap replaced also, they are going to be really nasty!
 
Damn m/m, you have definitely seen too muc of this shizz. After you sayin the shizz bout the light switch it all seems to fall into line. The light funkshunz fine when in hi range but dont wurk in lo range. Gotta be all shizzed up from mud and years of grime.
I'm just hopin the local trans shop has the gaskets for the case to tranny mount. I refuse to use rtv for that. And I guess I'm gonna need the seals on the shift rods too. Maybe they have a seal kit
 
The gasket and seal kit is a very common item, we have 'em in stock right now! But...ive noticed in the past that the "texas pattern" gasket between the trans and the tc is sometimes not cut correctly but it's easily modded! I normally make my own gaskets for that location using 1/32" composite rubber/fiber paper. That 1/32" paper dimension is important as that serves to keep the bull gear away from hard contact with the rear output shaft.

But before doing anything, verify full shift lever travel!

You remember yore neighbor/scoutbubba down there clay (dagator} from a few weeks ago???? He calls me one day with his rig stuck in the dam crick bottom while tryin' ta find sum wild pigs ta stick with an arrow and it won't engage 4low, first time that had happened! I happened to be at Jeff's shop when the call came in from clay. So Jeff and I went and looked atta d20 sittin' on the shelf.

When I called clay back, I told him the shift lever was not moving far enuff...sho-nuff, clay looked down and saw a matchbook had fallen down in the shift boot and that was just thick enuff to keep the lever from fully shifting the "fork/rod" to allow the poppet to snap into position! Up to that point, Jeff and I didn't think that was possible!

We sent clay a statement for "1.0 labor hours" for "telephone consultation while stuck in tha dam crick in southgeorgia"! He paid up witha case of patton's pride! I'll never forgit that story!!!!
 
Gonna du sum reesurchin tumaro on the body hittin thing if it aint that then I'll be a yankin da case. Will order frum yall if I cant source the stuff here it aint the prices its the damn shippin. Them gangsters at the ups big desk are gettin freakin Rich.
 
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