Suzuki Club UK

I took my sj out off roading for the first time since my rock lobster build, and have noticed that it will pop out of 4wd low.
I have read the following thread: http://www.suzukiclubuk.co.uk/phpBB3/ph ... =12&t=2612" onclick="window.open(this.href);return false; but you see mine only pops out now and then, most of the time its fine, but then if you go over loads of bumps etc then it will pop out occasionally.
What do you reckon it could be?

My SJ used to do this. The cause was over enthusiasm and lack of armour. The t/box mounts were bent and the t/box lever was catching on the tunnel. Just required some beating back into shape and a bit of extra reinforcement.

Jordi

I have used land rover v8 engine mounts as the mounts for my t box ( as recommended by the rocklobster build page ) They needed a bit of angle grinding though to fit onto the tbox properly and next to the handbrake drum. Not sure if it is these.

mine used to do this too, I had put a prop spacer on the rear prop and when the axle was moving occasionally it came up so far it pushed the box forward and the lever into the transmission tunnel, pop-ing (spelling?) it out, I cured it by putting a smaller spacer on the rear prop

I have a drum on my rear prop, so dont have a spacer

Also I have the exact same setup ( prop wise ) as before I done the rocklobster build, and it never used to pop out with the 413 tbox I had in there

Who built your tbox? Did they miss out one of the detent balls? If they forgot the one between the selecor shafts then this can happen, or it could be a problem with the front output shaft.

it might be as simple as you put the gaiter on the wrong way round

lol i was literally just typing this when you posted robbie... seems a shame to waste it :

Did you put the transfer gearstick gaiter on the right way round? I found out the annoying way, that it pulls the gearstick down from 4L into neutral!!!

Passenger has to hold the stick in gear

ScottieJ wrote:Who built your tbox? Did they miss out one of the detent balls? If they forgot the one between the selecor shafts then this can happen, or it could be a problem with the front output shaft.

I built the box and made sure everything went exactly where it should, the ball you mention, isn't that the ball that is taken out if you want to do the 2wd low mod? I left that in if thats what you mean, I also put the ball and spring in underneath. What could be wrong with the output shaft? I put 2 shims in on that shaft, as it seemed correct when checking the end float.
I will check the gaiter later, also I am wondering if it could be the rubber seal underneath the lever, as the case I have used is the 410 one and I had never tried it before taking it apart, where as the 413 one I had used and all worked fine. So I guess it might be worth swapping the seals over.
Also I have noticed that there is some play in my front prop, whether that would make any difference or not?