@hummerz quick question. If I can **** the tcase into neutral, and shift it into low and hear the clunk, can I assume the fork works? If that is the case, why is it still feeling like it's in 4hi lock when the 4hi only light is on? Why would I be able to get to 4lo but not full-time 4? Trying to wrap my head around the video. Thanks.

 

there are two forks in there. seems only one is broken

 

Ahh ok, thanks. Going to try to change the stepper as well in hopes I get lucky, but I did order a new aluminum fork. Just will need to find someone who can do it for me at a reasonable rate.

 

I would recommend that once that transfer case is open to take the opportunity to change the chain as they tend to stretch.

 

New day new discoveries. So had some time to clean the maf like @Doc Olds recommend. Also filled up with premium which hurt and dumped some fuel system cleaner in. Did a couple of 30 mins trips in 3 to keep the rpms up. Happy to report she is running nicely now with no CEL! Hopefully it stays that way.

On the transfer case front, found an old thread that recommended driving for a bit in reverse. Went down to a school nearby on a dead end and did a couple 1/8 mile runs in reverse and the transfer case unlocked! Got a few good hours in, but went back into lock on its own right at the end of the day. I did go over a large speed hump so I don't know if that has anything to do with it. Can anything be assumed from it being intermittent?

New discoveries: twice today power just when coming to a stop. Everything was fine and strong but just died with the red battery light illuminated. Started right back up but concerning to have it happen twice in a couple hours. Also it appears as if the rear diff is leaking so I am wondering if it locking on its own can have anything to do with fluid levels? I know doc recommended to change them, but I am hesitant to have that done if I am just going to need to have it cracked open soon to fix a fork.

Thanks all

 

have the battery terminals been replaced yet?

 

Does not appear so.

 

OK......... can we get this right. It is: Have you replaced the crappy azzed OEM Battery Terminal Connectors yet?

Replacing the OEM Battery Terminal Connectors with a quality aftermarket set , like Stingers or your favorite brand, is one of THE first mods to be done to every H3/H3T.

 

Just ordered the Stingers. Thanks.

 

I just went through this with my 08 Alpha. Here is what I learned. Finding a shop to tear apart a transfer case and replace a $20 dollar part is hard to find, at least here the NC OBX/South East VA area. I found one shop but not a very long warranty. I wound up getting a refurbished one from Transfer Case Express and had a local shop take delivery and swap them out.

Refurb transfer case with 2yr/70,000 mile warranty $1,220 w/shipping, takes about a week.
A local shop to swap them out for a bit over $400.

Your symptoms mirror mine.