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1996 Tracker Transfer Case
12-07-2007, 03:44 AM
Post: #1
Question 1996 Tracker Transfer Case
I have a '96 Tracker that is jumping out of 4H @ 30 mph. I am in need of an exploded view of the transfer case. If anyone has any other info on the cause of the problem I would appreciate it. Everything is tight - both shafts - the selector - etc. But @ 30 mph it kicks the selector right back into 2L.
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12-10-2007, 12:25 PM
Post: #2
RE: 1996 Tracker Transfer Case
Sounds like syncro or forks worn. Here are some pictures. Sorry for the delay in response.


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Cary Joe York
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12-10-2007, 08:39 PM
Post: #3
RE: 1996 Tracker Transfer Case
Thanks for the pics. Do you know if there are any adjustments that can be made with the transfer case in the vehicle? I read somewhere that loose or worn t-case mounts may cause the problem. When I hold the brake on & put it into forward or reverse there is a significant amount of movement of the selector. I am going to try to get it onto the rack within the next couple of days to check it out. Have you ever heard of this? By the way - for anyone that is interested I have found some manuals available for download @ http://www.suzukiinfo.com
Again thanks for the pics. I'll let you know what I come up with.
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12-14-2007, 01:41 PM
Post: #4
RE: 1996 Tracker Transfer Case
It is possable that something is loose at the shifter or t-case. Just check everything to make sure it is all tight. I have not heard of an adjustment.

Cary Joe York
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12-14-2007, 10:29 PM
Post: #5
RE: 1996 Tracker Transfer Case
Might be a dumb suggestion but have you checked the engine mounts to see if excess movement might be binding the linkage or pushing it with changing engine load?

Going from high to low range while under way has got to be causing a serious gear clash and that can't be good.

BTW, how does it go from high range to low range without passing through neutral? Is this some sort of electrc shifter?

Rupe
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12-15-2007, 09:17 PM
Post: #6
RE: 1996 Tracker Transfer Case
I must apologize. The selector is jumping from 4H back into 2H. There is no 2L. Starting from the rear position the shifter goes 2H > 4H > N > 4L at it's most forward position. I'm sorry for the misinformation. As you can see Rupe, it doesn't have to pass thru nuetral. Also, there is no exterior linkage. The shifter assembly is bolted directly to the top - similar to a toploader tranny. Next monday I'm going to get it onto the rack. Then I'll get a good look at all of the mounts and hardware. Thanks for your input guys. I'll let you know what I find out.
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12-22-2007, 04:52 PM
Post: #7
RE: 1996 Tracker Transfer Case
Well I had it up on the rack & everything is tight. We took the shifter out of the top & there are no signs of significant wear - actually you can bearly see any wear at all on the shiter end or the rails. From the looks of it - previous owners used 4-wheel drive very little. We ran it up & down a secluded road quite a few times with my buddy pushing it back into 4H everytime it would jump into 2H. It seems like pushing it in while moving gets it deeper into gear. We had it staying in 4H past 55mph @ times. I'm going to try using it more. Maybe it just needs more use to wear in. OK - I'm reaching for straws - but it's all I have @ the moment. I may buy the factory service sheets & see what I can find. Thanks for the assistance.
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12-23-2007, 10:28 PM (This post was last modified: 12-23-2007 10:32 PM by Rupe.)
Post: #8
RE: 1996 Tracker Transfer Case
I'm going to suggest that something is not right with either the shift rods or the detents that give you the "feel" that it's clicking into gear.

Short of major wear with the gears / bearings / shafts inside the trans this is not that big a deal to repair but unless someone is real sharp with this particular unit it will probably require removing the tranny from the vehicle.

On the outside chance we can gather another clue have you tried draining the gear oil to see what comes out?

Many T/F cases and transmissions have a magnetic drain plug and your clue might be stuck right there. (roll pin, snap ring, etc)

Of course any other sign of metal in the oil is also a hint at bigger problems. Brass and aluminum won't stick to the magnet but you can usually see the color with a shop light as the oil drains. Also look at the bottom of the drain pan and see what settles there after it sits for a few minutes.

Rupe
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