4lo not going into gear

I picked up a used 4Runner manual tcase - I'm on the fence about putting the manual tcase in vs. repairing the original tcase. But what is interesting, is that on the manual tcase, between 4H and 4L there is an 'official' neutral position, where the input shaft from the transmission is disconnected from either of the drive shafts. On my truck, my hypothesis is that my 4L shift fork is getting bound up in the neutral position - while neutral doesn't 'officially' exist as an option on the original tcase, I believe the internals are identical between the manual tcase and the actuator tcase, with the exception of the shifting mechanism.

This is another useful video, albeit long. Shows the complete tear down of the actuator tcase. Doesn't show the shifting in operation, but does show all the parts in detail.

https://youtu.be/DlOm8_Tt81c

 

If you’re willing to cut the hole in the floor for the 4Runner case, I’d say go for it.

I think that and the FJ tube/ADD delete has been my favorite mod to date. the ease of getting in and out of 4Hi and 4Lo is night and day.