Kzj78 low range help

[uptomynutsinruts]

Hi all,
Ever since I've had my Prado its always popped out of low 4, it happens under any load and also under deceleration, if I hold the lever in the low position it will stay in low but that's not always possible, any ideas what it could be?
Has 2 inch body lift and I am yet to pull the gearbox surround off to check the lever isn't touching the body at all but it doesn't feel as though it is. I really don't want to try and pull the transfer out if I don't have to but to me it seems that way.
Any help would be greatly appreciated

[mudlva]

Think you have already sumed up the problem

[Smurf]

This is of no help to you, but mine used to do it, I swapped in a replacement transfer case as I got offered one cheap from a KZJ78. I didn't have a body lift though, so that may not be your problem. I'm interested to know the outcome as I have never split the transfer to find out the issue. I probably should one day though??

[uptomynutsinruts]

Hey smurf,

Was it a bitch of a job to swap out? Only ever swapped gearboxs with xfer and bell housing still attached, never divorced a case off a box and replaced it

[Smurf]

piece of pi## to swap in place, just be careful splitting it and re attaching the transfer as there is a seal inside that can be damaged by the input shaft/coupler. Oh and make sure you refit the coupler, we missed it and had no drive so had to remove transfer again. Had transfer in and out twice in a matter of hours. removing the levers was probably the trickiest part as it is remote.

[uptomynutsinruts]

You've made my bloody day thanks heaps mate, been absolutely dreading doing it!!

[Smurf]

I was the same til it just had to be done. Its a heavy sucker but not too bad to lift off the back of the auto

[kbushnz]

Check your engine / tranfercase mounts... They really twist and move under load and combined with your lift could be pushing the leaver out of gear. Mine jumps out of low under heavy pto winch and drive loads.... Have to hold it in... once that gear starts moving it will just pop......

[The WEHI]

Check all Detent springs/and sensors make sure the rubber boot isnt restricting movement it may not touch the body but the boot can pull it out of gear
if its manual you'll have to disasemble the transfercase to get it out,

[tallsam66]

Make sure the leaver isn't fouling on the body. This exact problem can occur with surfs when body lifted. You might have to grind a bit off body to give the leaver clearance to go fully into low range.

[uptomynutsinruts]

Cheers fellas will have a look tomorrow, had to trim my old surf lever hole so hopefully this is the same or it just needs a new spring or something in the detent ball setup