Loosing my marbles-Sami transfercase

[Hoagie]

:D My son and I both have Sami rebuilds in progress. We have removed and reinstalled his transfer case four times(first time we installed trail gear 6.5 gears :) ) each time trying to figure out why his tc won't do 4wd. Each time we have tried something different to fix it like pressing the 4wd output shaft into different positions to try to get the gears to slide the output ring into the place thinking that the new hd output shaft needed to be in a slightly different position or that we hadn't pushed it far enough. Next attempt we learned/understood how the forks cause the gears to work. When we did the first one we made the mistake of removing the big fork shaft and not noting the positions of the shafts due to the marbles.Yesterday we tried again-remove tc, adjust fork position to different slots for the marbles. Reassembled and tried it out-still not in the right positon. I would like to know how to align the forks using the steel balls(marbles) to ensure that the 4wd will slide and engage. I know that each must be in the right position for engagement of 4wd. Your help is appreciated.
Hoagie

[Chris Geiger]

Check out our online instructions here...

http://www.trail-gear.com/tech/zuk65gears/index.html


If you still need additional assistance, please call us during regular business hours and ask for Andrew. He is our resident t-case expert. Our number is 559-903-0705. We can also make arrangements to complete the t-case for you.

[84_Yota]

http://i19.tinypic.com/6bn979j.jpg
This image is showing the 4wd shift fork (in the 2wd position) with a detent ball above it. When this shift fork is removed there is a spring and a second detent ball. The instructions do not show this because it is unnecessary to remove the 4wd fork, but if you did remove it you will need to compress the ball and spring with something like a screw driver while from the inner side of the cover while you install the shift fork from the outer. The third detent ball is installed at the very end once you have your case back together.

To sum it up for the location of the detent balls in the picture above, from top to bottom it goes:

Spring
Ball
High Low shifter
Ball
4wd shifter
Ball
Spring

If you have anymore questions let me know.

-Andrew

[Hoagie]

Andrew
Two questions.
1.When inserting the longer fork into the other hole showing the place where the ball is pressed down which of the dents in the shaft is the one to place the shaft into since I remember seeing three of them. when we reassembled last time we thought that our problem was that the fork was slipping not engaging the 4wd on the large gear shaft. It slipped and and just barely made it engage or could it be
2. since we removed the fork from the other shaft by driving the pin out of the shaft I suppose that there is a possibility that we rotated it around 180 degrees and installed the fork with the dents facing away or towards the fork. which way do the 3 dents go? Toward or away from the direction the fork faces??
We will remove it again for the 5th time some time soon. I hope you can look and see and figure how we made it to slip out of gear when trying to using 4wd.
Thanks for helping us figure out how to get our marbles together:hammer:
Hoagie

[84_Yota]

http://i18.tinypic.com/63j6v55.jpg

Hoagie,

Of your two points the second one sounds the most logical. The picture above shows the three detent notches facing away from the forks. I will double check tomorrow when I get into work, but it sounds like that is your problem right there.

-Andrew