Introduction
This document outlines a common issue encountered with selecting High Lock (HL) or Low Lock (LL) on the transfer case, particularly in warm conditions. The shift lever may become jammed, preventing selection of these modes. This is commonly reported for 95 Series vehicles.
Problem
The transfer case selector lever becomes jammed, preventing selection of HL or LL modes. This may occur after the transfer case has been operating at higher temperatures. Reversing or other ‘windup’ mitigation techniques may not resolve the issue.
Solution
The issue can be caused by misalignment or deformation of the spring/s in the shift mechanism.
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Inspect the shift linkage: Check for any obstructions, bends, or damage to the linkage.
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Inspect/Replace Selector Spring: The selector spring may be bent, causing the mechanism to jam. Replacing the spring may rectify the issue.
Relevant Parts
- Replacement Selector Spring (Part number not provided, consult Toyota parts catalogue).
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