Big time center diff problems

[Huw Powell]

>     I just finished replacing the clutch on my 86 4000csq and now the
> transfer case seems to be stuck in neutral.  The clutch seems to be
> operating fine, however, when you put the car in gear and let out the
> clutch the transfer case grinds like crazy and the car doesn't move.

Well, it's not a transfer case, but anyway I'll take a stab it this - it
doesn't sound like you are actually getting the car into gear.

The center diff. is always "engaged," it is just locked or unlocked when
you switch it.

The 4kq shift mechanism is a real nightmare of a setup.  You may
discover that one of the many rods or levers is not properly attached,
or that it is not properly adjusted.

I like to use reverse when doing a "seat of the pants" adjustment (read:
no proper tools).  Since 1. you can get confirmation that it is actually
in the gear you think it is from the backup lights, and 2. reverse
requires you to push down to avoid the lockout mechanism, it's the most
"precise" gear to fiddle around with.  Then just make sure the others
engage as well before washing your hands.

The "proper" way (I think) is to have the tranny in neutral, ie at the
middle "rest" position, and use a tool to hold the shift lever dead
center while tightening it up.  But that is tough without the centering
tool.

--
Huw Powell

http://www.humanspeakers.com/audi/

http://www.humanthoughts.org/