After doing all of the revival work described in this playlist, I was dismayed to find that the vehicle would not come out of four wheel drive. I researched for months and found that there is no a lot of information out there that explains how the front drive and selector mechanism work, much less explanations about why it might NOT work. It seemed to me that the more likely failure mode would be not going into 4WD. After verifying the presence and operation of all of the external controls, I was faced with the choice of sending it back to the farm stuck in 4WD for use as a utility vehicle, or dive in and find out what was amiss. I originally hoped I could pull the front drive unit off with the transfer case in place. No way - the whole thing had to come out. There is a lever that is attached to the yellow 4WD plunger that is supposed to lock the front drive engaged. It was not behaving properly. Remember that. In the video you will see that when I drained the case and removed the oil pan, One of those lever assemblies FELL OUT. How did it get in there? Why did it not get in the gears and destroy them? It has some scars from coming in contact with them, but was basically ready to be pressed back into service. I proceeded with the removal of the transfer case and in the process found out that the 4WD selection mechanism was now working! I guess the errant lever had jammed the selector shafts. I'll never know for sure. But the project gave me the opportunity to replace leaky seals and gaskets an renew the intermediate gear shaft and bearings.
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Land Rover Series II Transfer Case Remove, Fix, and Install
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