Offroad-Express

Hello all. Wondering does anyone know anything on the original setup on the transfer case on a 1980 bj 42 regarding 2wd to 4wd transfer? I am currently stuck in 4wd. I have heard of some reference to a transfer button on the dash?? Thanks

I'm pretty sure all 40 series just have the transfer lever on the tunnel to the right of the gearstick. It can get pretty hard to move out of 4WD if you're on hard ground and there's a bit of wind-up in the drive-train. It usually pops out if you hold a bit of pressure on the transfer lever & jolt the clutch in reverse. If that doesn't work, try jacking up a wheel to relieve the tension in the drive-train, but be careful - the wheel will spin a bit as the pressure comes off. If nothing happens & it doesn't come out easy after that, I suspect you've got a transfer case problem....

sometimes 'old rusty' (refer to avatar on the left) doesnt want to go into 2wd high.. i suspect this could be a bit of wind up.. ya could try what i do and just let the clutch out just a little to get a slight roll on and then put the clutch back in and try movin the transfer gear lever again? works ok..

or man handle the bastard! it'll take it, after all, its a 40!

All my 40's used to get bound up in 4WD, I always used to back up and slip it out of 4WD and it came out every time!

Thanks for the replies. Will try and be a bit more presuasive.

I had a similar problem with a 77 FJ40 staying in 4WD. I found that before I brought it someone had carried out some work on the transfer case and reversed the splined collar that runs off the fork in the transfer case - engaging/disengaging 4WD. It only catches by approx 1-1.5mm when reversed (on my one atleast) but enough to not allow the front shaft to release. Simple enough to pull apart. Good luck Stef

Thanks for your suggestions. Tried them all except for transfer case removal but still stuck in 4wd. Just wondering if anyone has heard of a vaccum pump above the transfer case that allows the switch between 2 and 4wd? There appears to be a vaccum pump of some type when i examined the transfer. This then points back to a button switch on the dash that has gone missing over the years.

sounds like mine, i have the h55 gearbox/transfer case and yes it does have a vacuum actuator for 4wd, although i'm pretty sure it only engages in 4wd high. Where abouts are you? if not to far away, i could have a look if you wanted.

That would be sweet but i'm all the way down in Queenstown. Wondering does anyone know where i might get a replacement switch for 2wd to 4wd? I found mine broken behind the dash. It appears to be making a vaccum sound when switched but the knob is broken. I am now going to trace the piping to see if anything is blocked or open. Anyone with other similar experiences suggestions would be great.

Early Range Rovers have a vaccum switch for centre diff lock.
Fit a 5 port 2 position air switch, simple and because of the pressure they withstand they are better quality.
You need 5 ports to have 2 exhaust ports
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