Dual Range Stick Is Stuck

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jackmacpajson
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My 2002 io 3drs dual range superselect stick is stuck in 4H and has been for a while. Someone suggested that it might be linkages. 

NEED HELP  PLEASE

Claude io
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dual range stick

jackmacpajson wrote:

My 2002 io 3drs dual range superselect stick is stuck in 4H and has been for a while. Someone suggested that it might be linkages. 

NEED HELP  PLEASE

Welcome to the forum if you are in Canberra,  more than happy to help. If not this subject have been covered a few time and you can read a bit more about it in a few location, here included

http://pajerio.com/forum/4wd-gear-stick-jammed-1999-pajero-io-18

Happy io

bob_oz
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super select stuck

I fixed this on the weekend past. - not difficult and ok for beginer etc.

your shift bush is likely shot or on the way out, part MD701605
it causes the stick to not lift back up fully or to over lift up out of the shift tab

you can temp fix it by unbolting the shifter and cleaning out the bush

* unscrew transfer lever knob off
* two screws in cup holder then pull rear consoule off (clips on at front)
* unscrew 6 screws holding rubber boot to floor
* reach down through the floor hole and unbolt the 3 x 12mm bolts holding the shifter into the transfer box
* from underneath - gently tap the shifter base that was bolted down up with a screw driver (items below 30627 and 30641)- there are 3 thin metal and gasget layers in the sandwich bolted to the box that come off in one piece with the shifter.

* once shifter is off pull the bottom domed steel washer off and look up into the shifter mechanism - likely just needs a flush out or bush replaced

* if bush is rooted - order one and re-assemble sadwiching with a super thin bead of bluemax silicone (clean surfaces first)

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to replace old bush with a new unit see below. 
it is easier to massage the rubber boot off and up to remove the spring circlip.

support the rod when you drive out the pin and use a flat punch so you son't bruise the pin. - take note of length offset etc and expect to need a minor adjustment once it is seated back in the cup (tight to get bush + pin back into cup in final offset)

old VS new

 

 

 

back together

.

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