06 H3 won't come out of 4 lo lock

[Dans06]

New here and at my wits end with this problem. After two months of owning my 06 H3 I exploded the tailshaft housing . I bought a rebuilt transfer case from a chain store because I knew someone who worked there and got me a good deal. Five months later stopped to get fuel, came back out to leave and it's in 4 low lock and won't come out. got some friends to get it trailered back home. Pulled out the tc and pulled it apart. Only thing I found wrong was that the hi/low fork inserts were junk and cracked the fork. Bought a new fork and installed it. Everything shifted fine while on the ground and manually shifting thru the ranges. as soon as I put it in and tried to put the encoder motor on it would not line up. had the case in the high position and the encoder motor also in that position. Tried the running through the buttons with the encode plugged in but hanging, seemed to work as it should, even tried another encoder motor with the same results. Tried to move the h3 and it's in low lock even though the buttons show it's in 4 high. Just want this thing back on the road.
Sorry this is so long but wanted to give as much detail as possible. I'm thinking tccm, but am open to any suggestions. Don't want to just throw money at it and hope I guess right.

 

[alrock]

Thanks for the detailed write up of your situation! Question for you - if the transfer case is manually shifted to 4 high, how can it be in 4 low when you are driving?

 

[Dans06]

Good question. thats why I'm dumbfounded. Dash shows it in hi but it is still in low lock. Just cleaned the dash buttons,were not dirty, but you never know.

 

[alrock]

Let's assume you put it in 4 high unlocked manually and leave the encoder motor detached from the transfer case - how does it drive then? I think you need to verify whether this is internal to the case (not picking on your skills but its feasible to miss something) or something outside of the case.

My H3 had a brain fart (that's what I'm hoping it is) and slipped into 4 high lock from regular 4 high yesterday. I was able to turn off the truck, restart it, and cycle through the modes getting it back to a normal operating condition. I too was checking for sticky buttons but the buttons hadn't been used or accidentally hit.

 

[4speedfunk]

Could be the t-case was assembled incorrectly. There is a pretty specific procedure to get all the internals aligned with each other, so it functions correctly. There are a series of alignment marks on the planetary gears that must be oriented to line up with marks on the sun gear...sort of like timing marks on camshafts. You can download the t-case service manual from Schwartzzy.com

 

[Dans06]

I will pull it apart one more time and let you guys know. I did have a pdf in front of me when reassembling but I may have missed something. Again I will let you know what I find. Thanks for the replys.

 

[Dans06]

Ok. Nothing new . Everything Looked and acted as it should while on the floor, manually shifted it and all the modes worked as they should. put it back in , left encoder motor off and still in low lock, even though shift shaft is in the hi position. does not make any sense to me. Glad neighborhood kids are at school, they would have learned some colorful new words. Stumped. This is why I think it's in the electronics. Help please, need this going by the end of the week.

 

[alrock]

I'm not clear on how it could be the electronics if the electronics were essentially disconnected from the transfer case. If the encoder motor is detached, and the TCCM controls the encoder motor, how can it be electronics? I'm not sure of any electronic connection to the transfer case other than a speed sensor. The physical gearing controls the speed, not the TCCM. The binding of the wheels when turning with the transfer case locked is a mechanical issue.

I'm assuming the transfer case can also be manually spun when it is disconnected from the drivelines. If so, if it's in 4 high the output speed should match 1:1 the input speed. If it's in 4low, the output should be about 1/2 to 1/4 the input speed.

I have not disassembled transfer cases myself so I apologize that I can't give you assistance on what to look for with the case.

 

[Dans06]

Sorry no update for a bit. Had someone who rebuilds transfer cases for a living tear it down and check everything, no problems found and it's still stuck in low lock.

 

[alrock]

So the question is: when you have it on the bench and test it, it's a 1:1 output from the input shaft to the output shafts? And when you put it in the truck and don't connect the encoder motor and just connect the front and rear driveshafts, it suddenly moves to 4 low?

 

[Dans06]

Yes.

 

[Dans06]

If I could get my hands on a nr4, I would put it in. I don't wheel at all, so the 4:1 is useless to me anyway.

 

[650Hawk]

With the encoder motor off, you should be able to see the input where the shaft of the encoder motor goes; Is it changing position between sitting on the bench and sitting installed into the truck?

 

[Dans06]

No it's not. Damndest thing I ever seen. So sick of this thing. Dynamite is a viable option at this point.

 

[650Hawk]

If the input (where the encoder motor installs) isn't changing position, but the TC is switching from 4HI to 4LO, then there is something internal that you're missing; no other possibility.

 

[Dans06]

Put a different case in. Up and running for now. Thanks to all that commented.