Transfer gear lever popping out

[maxwellstreet]

The transfer gear lever on my '99 Td5 Automatic has started popping out of high and into neutral. (This usually happens when there is no hard shoulder on the motorway!)

I think I might have caused a problem when I tried reversing my trailer to free up siezed wheels on the trailer. Although not putting a great deal of power on, I was pushing against an immoveable object. Thereafter, I noticed a slight whine from the transmission, and about 300 miles later the transfer gear lever started to slip out into neutral.

The slipping has become increasingly frequent, from about once every 30-40 miles to once every 20-30 miles, before I had the bright idea of tying the gear lever into position to get me home.

Any ideas on how to solve the problem?

[BrianH]

Not sure if this is going to help you, but on my Discovery there's a bit of a knack to shifting between high and low range and, if it's not done properly, the transfer box gear lever will sometimes pop out. This is because the lever doesn't always push all the way home, even though it feels as if it does and the vehicle will initially drive down the road in the selected mode.

In order to ensure that the lever goes all the way home I have to do the following:

1. First put the vehicle into the gear you want
2. Then push the transfer lever into the mode you want and, while still pushing the transfer gear towards the mode you want (whether it be high or low), begin to gently lift the clutch.

The transfer gear lever will then suddenly "bump" all the way home into it's correct position and after that, it wont come out.

Try this on yours.

Hope this helps

Brian

[TheGurkha]

On odd days (no discernible pattern as to why) I have to do as BrianH says on the Gurkha. Other days it's 'normal' :rolleyes:

[maxwellstreet]

Thanks


Guys - really appreciate the posts - unfortunately I'm 100% confident that the lever was properly located at the full extent of the slot.

In fact, I have seen the lever pop forward about 1/4" within a few miles of being engaged, thereafter at some point it will pop further out into neutral.

My local garage, who is excellent, reckons it means a replacement transfer box. Obviously I'm now desperate to find any other (less expensive) diagnosis!:sobbing: Any other ideas?? Thanks

[JonS]

Your garage may already have checked this out, but the high/low selector on the D2 is cable operated, and the picture in the book shows that there is scope for adjustment.

This means there is also scope for maladjustment :D - and just because the internal selector is in the right place doesn't guarantee that the lever on the transfer box has gone as far as it ought.

Worth a look before you buy any more cogs!

Regards

Jon