What could cause a 1987 Suzuki Samurai transfer case to lock in neutral when shifting from 4h to 2h?

Answer 1

This happened to us recently while we we replacing a worn u-joint. Still do not know the answer but will let you know if we get an answer. Were you able to get it out of neutral and how?

Your shifter sheet(bushing)is worn out. Mine just recently had this problem. It is an easy fix but a messy one. You have to remove the shifter from the T-case and clean out the old shifter sheet. You most likely will have to reallign the shift forks inside the t-case. Do this with a long flat blade screwdriver. When the forks are in line the shifter will fall back into place. Press the new shifter sheet into place and replace other parts. The new sheet will have exact instructions with it. It will cost you about $10 for the rubber one or $20 for the poly one. I recommend the poly sheet as it will last the lifetime of the truck. While you are at it you might as well do the transmission shifter sheet too. my name is Danny. i have a 89 zuk. Sammy. my t-case had same prob. so i put a sheet back in. it worked fine then i found a poly. sheet for it when i had same prob with my tranny. when i took rubber sheet out it was already worn in places just after a few months now i have a poly. bushin in tranny and t-case and both shif better then ever has and seems to be Holden u alot longer then rubber. that's a tip to help u save time and a chance of gettn stuck on trail