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There is a part called the Shifter Sheet by Suzuki. This rubber part sits below the shifter ball in the top of the t-case. When it dries up and crumbles away the t-case shifter can get stuck. A new part is only a few dollars and is easy to replace.

If you have this issue, you also probably have a sloppy shifting 5 speed transmission. A new "shifter bolt" will fix this issue.

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Q: What would cause the transfer case shifter to not shiftto any gear?
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How do you replace shifter sheet in 86 suzuki samurai transfer case?

I just did this in my '86 because the transfer case would not shift I had to remove the shifter and realign the two shifting rods inside to get it out of neutral. Pull the shifter boot off the floor. Pull up the transfer case boot under the floor boot. remove the shifter by using a couple of screwdrivers to push down on the ring around the shifter at the bottom and turn CCW (1/4 turn), this will release the spring loaded catches that hold the shifter in (don't worry you will not lose anything). When you extract the shifter you will see the 'ball' on the shift lever, the shifter sheet is what this ball sits on inside the transfer case. It is a cupped shaped piece of plastic like nylon and is often long ago disintegrated and missing, if not, pull it out and put in the new urethane or brass sheet and put everything back together. Hints: be sure to eliminate any burrs on the shifting ball that will cause premature failure of the sheet by filing them off.


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