Transfer case stuck 1/2 way between gears - Dodge Cummins Diesel Forum
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98.5-02 Powertrain Discussion of components that are directly involved in the power production and all that is needed to get and keep the truck moving . Engine , Transmission Ect..NO ADVERTISING .

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Old 08-25-2009, 12:59 AM   #1 (permalink)
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Transfer case stuck 1/2 way between gears

Just put 5th gear back on. After re-assembly, started it up and the transfer case seemed to get caught half way between 2h and 4h. Discovered a vacuum problem and fixed it. Now how do I get it to fully engage in either 2h or 4h?
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Old 08-25-2009, 03:09 AM   #2 (permalink)
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Try rocking the truck while pushing on the lever. If that doesn't work something wasn't reassembled properly.
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Old 08-25-2009, 06:55 PM   #3 (permalink)
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Is the set screw on the shift leaver linkage in the right spot on the rod coming out of the TC? Maybe loose? Does it feel like its shifting when you move the shifter?
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Old 08-25-2009, 09:21 PM   #4 (permalink)
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shut truck off move t-case handle into 4h-2h see if it moves again it might be your linkage improperly adjust or reassembled wrong
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Old 08-25-2009, 09:22 PM   #5 (permalink)
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it feels like it is shifting, but only between 2h and 4h, won't go into N or 4h. Vacuum pressure changes along with 2h/4h and front axle locks in/out too. someone suggested I might have gears out of sync in the tcase. I will not have help to rock/try to shift until saturday as it's on a declined driveway right now It shifted through all 4 easily before starting it (so i don't think it's the lever), but had bad vac pressure and didn't realize it.
I think I might have to get into the transfer case. I've read threads stating "its possible to do while still on the truck" and "it's not rocket science". I'll dig through the manual more tonight.
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Old 08-26-2009, 01:34 PM   #6 (permalink)
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What all did you do with the transfer case? Did you split the transfer case? Check out page 2488/2889 of the manual for the lever adjustment procedure. Of course it asks you to raise the vehicle, but you can disconnect the drive shafts to get the same results, just make sure to chock the wheels or it will take a trip down the driveway with you probably wrapped around the drive shaft. Try spinning both front and rear outputs and move the lever first to see what happens. Let us know what you find out.
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Last edited by Shainer; 08-26-2009 at 01:45 PM.
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Old 08-26-2009, 09:25 PM   #7 (permalink)
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who's dog is drivin', shainer? what do you mean what did I do to it? I jacked it up that's what I did, thanks to some not-so-helpful advice I received from someone who will remain nameless. I need to get one of those bad advice filters installed on my head instead of this hand
I waved sadly goodbye tonight as it took a ride to the 4x4 shop on a tow rig. Thankfully it's very close to the new house and he's charging me $50 instead of our guestimated $150 for towing. Will keep you up to date with status of "garage repair gone wrong".
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Old 08-26-2009, 09:44 PM   #8 (permalink)
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Right on. Always sad to see it on a tow truck though. I was trying to get all the details out there for better answers. Guess we will know soon enough. Hopefullly its a simple lever adjustment.
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