Solved 1991 Mazda Navajo Manual transfer case?

[NavajoHeadAche]

Hey everyone!

So I bought this Navajo a year ago with 97K on it. I thought it looked like a nice truck and would be decent with the lower mileage. It test drove fine but on the way home it became apparent the A/T was bad and would shift properly. So I had a new one installed. Then a few months later the front left wheel hub broke which gave me 3 wheel drive. The "push button 4x4" rarely works and I have to press it repeatedly, or turn the truck off and back on and keep trying to finally get it into 4x4. I think the entire system is trash.

Is there a way to convert the push button 4x4 to a manual type? I wasn't sure if there was a part that might replace the weak servo with a lever and cable.

Thanks!

 

[RangerX]

Yeah, the auto hubs don't last forever, and your 22 year old ones are way past their expiration date! Get manual hubs.

For the T-case, you can swap in a whole manual shift case, or bolt on a Shiftster to replace the shift motor.

 

[NavajoHeadAche]

This is great, but do they have one with a cable and mountable shift lever? I don't 4 wheel this truck for recreation. I only need the 4 wheel occasionally when I am at the beach. It would be a really pita to have to crawl underneath the truck each time I back my jet ski into the water.

 

[Roadrunner777]

2¢ This sounds like shift motor problems. I suggest checking these 2 threads out:

http://www.explorerforum.com/forums/showthread.php?t=202166

http://www.explorerforum.com/forums/showthread.php?t=123542

There is a little rubber bumper that tends to get squished up and cause such issues.

To your direct question, I have read about many attempts at a manual shift linkage for this transfer case. They all seemed to be a lot of fabrication, and experimenting. If that's your thing, look around... the threads are here somewhere.

 

[RangerX]

This is great, but do they have one with a cable and mountable shift lever? I don't 4 wheel this truck for recreation. I only need the 4 wheel occasionally when I am at the beach. It would be a really pita to have to crawl underneath the truck each time I back my jet ski into the water.

Somebody makes and sells one that's really nice quality for around $350. You could buy and install a manual case for lots less.
The shiftster is $50. For the price, it's not that hard top reach under and shift, I did that for years, before finally swapping in a manual.
I'd give fixing the motor a shot, using Roadrunner's links. It's free, and not hard.

 

[NavajoHeadAche]

Ok I'll look for those. I think I know the pictures you're talking about. The ones that depict the broken bushing. Would this also cause the Hi-Low range to become intermittent? I got stuck in low last night and it was aggravating driving down the street with a 45 mph top speed.

 

[NavajoHeadAche]

Thanks for the info guys!

 

[NavajoHeadAche]

Ok so I went through the servo and found the bushing was broken into crumbs. I made a steel bushing from a spacer and replaced it. It works perfect now like never before! Instant shifting with the buttons without any delay or malfunction!

I installed the new wheel hub and everything works like new. I used to have to repeatedly press the button, or listen to the relay clicking as it tried to engage. I thought it just wasn't lining up in the transfer case, but it was that bushing all along.

Thanks for the info guys! I REALLY appreciate it!

 

[RangerX]

Great news! Thanks for letting us know.

 

[jd4242]

Did you have stock front end? Because if you do, you haven't had any power going to either wheel if you lose a hub.the front stock is an open, for it to work both hubs HAVE to be locked in.....