Hard to shift transfer case into 4 high 2000 GV Suzuki

Have it check for DTC'S - diagnostic trouble codes ?
GEM Diagnostic Trouble Code (DTC) Index
GEM Diagnostic Trouble Code (DTC) Index DTC Description Source Action C1728 Transfer Case Unable to Transition Between 2H and 4H GEM CARRY OUT the electronic shift function test. REFER to Function Test - Electronic Shift in this section. C1729 Transfer Case Unable to Transition Between 4H and 4L GEM CARRY OUT the electronic shift function test. REFER to Function Test - Electronic Shift in this section. P0500 Vehicle Speed Sensor (VSS) Malfunction GEM GO to Pinpoint Test F . P1804 Transmission 4-Wheel Drive High Indicator Circuit Failure GEM GO to Pinpoint Test H . P1808 Transmission 4-Wheel Drive Low Indicator Circuit Failure GEM GO to Pinpoint Test I . P1812 Transmission 4-Wheel Drive Mode Select Circuit Failure GEM GO to Pinpoint Test E . P1815 Transmission 4-Wheel Drive Mode Select Short Circuit to Ground GEM GO to Pinpoint Test E . P1819 Transmission Park/Neutral Position Switch Short Circuit to Ground GEM GO to Pinpoint Test F . P1820 Transmission Transfer Case Clockwise Shift Relay Coil Circuit Failure GEM GO to Pinpoint Test E . P1822 Transmission Transfer Case Clockwise Shift Relay Coil Short to Battery GEM GO to Pinpoint Test E . P1828 Transfer Case Counterclockwise Shift Relay Coil Circuit Failure GEM GO to Pinpoint Test E . P1830 Transmission Transfer Case Counterclockwise Shift Relay Coil Short Circuit to Battery GEM GO to Pinpoint Test E . P1832 Transmission Transfer Case Differential Lockup Solenoid Circuit Failure GEM GO to Pinpoint Test G . P1834 Transmission Transfer Case Differential Lockup Solenoid Short Circuit to Battery GEM GO to Pinpoint Test G . P1865 Transmission Transfer Case Contact Plate Power Short to Ground GEM GO to Pinpoint Test E . P1866 Transmission Transfer Case System Concern - Servicing Required GEM CARRY OUT the electronic shift function test. REFER to Function Test - Electronic Shift in this section. P1867 Transmission Transfer Case Contact Plate General Circuit Failure GEM GO to Pinpoint Test E . P1876 Transmission Transfer Case 2-Wheel Drive Solenoid Circuit Failure GEM GO to Pinpoint Test G . P1877 Transmission Transfer Case 2-Wheel Drive Solenoid Circuit Short to Battery GEM GO to Pinpoint Test G . - For All Other DTCs GEM GO to Section 419-10 .
Your best bet , take it to a qualified repair shop that has the diagnostic tool to trouble shoot .
Principles of Operation
Transfer Case - Electronic Shift
The four-wheel drive, electronic shift-on-the-fly feature electrically shifts the vehicle transfer case between 2WD, 4X4 HIGH, and 4X4 LOW. The system mode is selected by the operator through the mode select switch (MSS) on the instrument panel. The operator is informed which mode the system is in by two instrument cluster indicators, one for 4X4 HIGH which is 4X4, and one for 4X4 LOW which is LOW RANGE (in 4X4 LOW both the lamps are on). Shifts into 4X4 HIGH can be made at any speed. When shifting into 4X4 HIGH with the vehicle stationary, tooth blockage may occur, preventing shift completion. When the vehicle is driven above 8 km/h (5mph) the shift will complete. When shifting in or out of 4X4 LOW, the generic electronic module (GEM) requires that the vehicle speed be less than 5 km/h (3 mph), the brake pedal be applied, and the transmission in NEUTRAL (automatic transmission) or the clutch pedal be depressed (manual transmission). (The digital transmission range [TR] sensor informs the GEM when the automatic transmission is in the NEUTRAL range position.)
The gearmotor encoder assembly is mounted externally on the transfer case. It drives a rotary cam which moves the mode fork and the range fork within the transfer case between the 4X4 HIGH, 4X4 LOW, and 2WD range positions.
The GEM uses two relays to control the gearmotor encoder assembly shift between 4X4 HIGH, 4X4 LOW, and 2WD modes. The GEM controls the pulse vacuum hublock (PVH) solenoid which supplies engagement and disengagement vacuum to control the hublocks.
The GEM accomplishes shifts by interpreting inputs from:

• mode select switch (MSS)
• vehicle speed signal (transmitted from the ABS system)
• gearmotor encoder plate position
• brake pedal switch
• digital transmission range (TR) sensor (automatic transmission)
• clutch pedal position (CPP) switch (manual transmission)
• ignition switch

Based on these inputs, the GEM controls the shifts into 2WD, 4X4 HIGH, or 4X4 LOW with the following outputs:

• low to high relay (clockwise)
• high to low relay (counterclockwise)
• pulse vacuum hublock (PVH) solenoid
• gearmotor encoder assembly

The electronic shift-on-the-fly (ESOF) system has a feature which allows the driver to override the vacuum operated hublocks. When the front hublocks are manually turned to the LOCK position, the hublocks are locked at all times, overriding the vacuum operated system. If the front hublocks are manually turned to the AUTO position, the hublocks can only be locked by turning the MSS to 4X4 HIGH or 4X4 LOW position.

On the transfer case
Transfer Case - Electronic Shift
The four-wheel drive electronic shift-on-the-fly feature electrically shifts the vehicle transfer case between 2WD, 4WD HIGH, and 4WD LOW. The system mode is selected by the operator through the mode select switch (MSS) on the instrument panel. The operator is informed which mode the system is in by two instrument cluster indicators: one for 4WD HIGH which appears as 4WD, and one for 4WD LOW, which appears as 4WD LOW. Shifts into 4WD HIGH can be made at any speed. When shifting into 4WD HIGH with the vehicle stationary, tooth blockage may occur preventing shift completion. When the vehicle is driven above 8 km/h (5 mph) the shift will complete. When shifting in or out of 4WD LOW, the four-wheel drive (4WD) control module requires that the vehicle speed be less than 5 km/h (3 mph), the brake pedal be applied, and the transmission be in NEUTRAL (automatic transmission) or the clutch pedal be depressed (manual transmission).
The gearmotor encoder assembly is mounted externally on the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the 4WD HIGH, 4WD LOW, and 2WD range positions.
The four-wheel drive (4WD) control module controls the gearmotor encoder assembly that shifts between 4WD HIGH, 4WD LOW, and 2WD modes.

Manual shift or Four-Wheel Drive Systems - Electronic Shift I'm assuming you have electronic shift because you refer to relay clicking behind the instrument panel . Principles of Operation Transfer Case - Electronic Shift
The four-wheel drive, electronic shift-on-the-fly feature electrically shifts the vehicle transfer case between 2WD, 4X4 HIGH, and 4X4 LOW. The system mode is selected by the operator through the mode select switch (MSS) on the instrument panel. The operator is informed which mode the system is in by two instrument cluster indicators, one for 4X4 HIGH which is 4X4, and one for 4X4 LOW which is LOW RANGE (in 4X4 LOW both the lamps are on). Shifts into 4X4 HIGH can be made at any speed. When shifting into 4X4 HIGH with the vehicle stationary, tooth blockage may occur, preventing shift completion. When the vehicle is driven above 8 km/h (5mph) the shift will complete. When shifting in or out of 4X4 LOW, the generic electronic module (GEM) requires that the vehicle speed be less than 5 km/h (3 mph), the brake pedal be applied, and the transmission in NEUTRAL (automatic transmission) or the clutch pedal be depressed (manual transmission). (The digital transmission range [TR] sensor informs the GEM when the automatic transmission is in the NEUTRAL range position.)
The gearmotor encoder assembly is mounted externally on the transfer case. It drives a rotary cam which moves the mode fork and the range fork within the transfer case between the 4X4 HIGH, 4X4 LOW, and 2WD range positions.
The GEM uses two relays to control the gearmotor encoder assembly shift between 4X4 HIGH, 4X4 LOW, and 2WD modes. The GEM controls the pulse vacuum hublock (PVH) solenoid which supplies engagement and disengagement vacuum to control the hublocks.
The GEM accomplishes shifts by interpreting inputs from:

• mode select switch (MSS)
• vehicle speed signal (transmitted from the ABS system)
• gearmotor encoder plate position
• brake pedal switch
• digital transmission range (TR) sensor (automatic transmission)
• clutch pedal position (CPP) switch (manual transmission)
• ignition switch

Based on these inputs, the GEM controls the shifts into 2WD, 4X4 HIGH, or 4X4 LOW with the following outputs:

• low to high relay (clockwise)
• high to low relay (counterclockwise)
• pulse vacuum hublock (PVH) solenoid
• gearmotor encoder assembly

The electronic shift-on-the-fly (ESOF) system has a feature which allows the driver to override the vacuum operated hublocks. When the front hublocks are manually turned to the LOCK position, the hublocks are locked at all times, overriding the vacuum operated system. If the front hublocks are manually turned to the AUTO position, the hublocks can only be locked by turning the MSS to 4X4 HIGH or 4X4 LOW position.
Do you know what DTC'S - diagnostic trouble code's are ?
GEM Diagnostic Trouble Code (DTC) Index
GEM Diagnostic Trouble Code (DTC) Index DTC Description Source Action C1728 Transfer Case Unable to Transition Between 2H and 4H GEM CARRY OUT the electronic shift function test. REFER to Function Test - Electronic Shift in this section. C1729 Transfer Case Unable to Transition Between 4H and 4L GEM CARRY OUT the electronic shift function test. REFER to Function Test - Electronic Shift in this section. P0500 Vehicle Speed Sensor (VSS) Malfunction GEM GO to Pinpoint Test F . P1804 Transmission 4-Wheel Drive High Indicator Circuit Failure GEM GO to Pinpoint Test H . P1808 Transmission 4-Wheel Drive Low Indicator Circuit Failure GEM GO to Pinpoint Test I . P1812 Transmission 4-Wheel Drive Mode Select Circuit Failure GEM GO to Pinpoint Test E . P1815 Transmission 4-Wheel Drive Mode Select Short Circuit to Ground GEM GO to Pinpoint Test E . P1819 Transmission Park/Neutral Position Switch Short Circuit to Ground GEM GO to Pinpoint Test F . P1820 Transmission Transfer Case Clockwise Shift Relay Coil Circuit Failure GEM GO to Pinpoint Test E . P1822 Transmission Transfer Case Clockwise Shift Relay Coil Short to Battery GEM GO to Pinpoint Test E . P1828 Transfer Case Counterclockwise Shift Relay Coil Circuit Failure GEM GO to Pinpoint Test E . P1830 Transmission Transfer Case Counterclockwise Shift Relay Coil Short Circuit to Battery GEM GO to Pinpoint Test E . P1832 Transmission Transfer Case Differential Lockup Solenoid Circuit Failure GEM GO to Pinpoint Test G . P1834 Transmission Transfer Case Differential Lockup Solenoid Short Circuit to Battery GEM GO to Pinpoint Test G . P1865 Transmission Transfer Case Contact Plate Power Short to Ground GEM GO to Pinpoint Test E . P1866 Transmission Transfer Case System Concern - Servicing Required GEM CARRY OUT the electronic shift function test. REFER to Function Test - Electronic Shift in this section. P1867 Transmission Transfer Case Contact Plate General Circuit Failure GEM GO to Pinpoint Test E . P1876 Transmission Transfer Case 2-Wheel Drive Solenoid Circuit Failure GEM GO to Pinpoint Test G . P1877 Transmission Transfer Case 2-Wheel Drive Solenoid Circuit Short to Battery GEM GO to Pinpoint Test G .
Your best bet , take it to a qualified repair shop .

For gear shift issues and gear stuck issues,the help links are provided below. Click the link below to go through troubleshooting procedure:---- ---- Car will not move when in gear?

http://repairhelpcenter.blogspot.in/2012/02/car-will-not-move-when-in-gear.html ---- transmission sticks in first gear? http://technoanswers.blogspot.com/2012/01/mercedes-benz-transmission-sticks-in.html ----- Transmission not engaging in first gear? http://technoanswers.blogspot.com/2012/01/mercedes-benz-not-engaging-in-first.html ----- Vehicle only goes in First gear?

http://howtobyme.blogspot.com/2011/11/chrysler-pt-cruiser-only-goes-in-first.html

----

Car is stuck in park and the shift will not move?

http://howtobyme.blogspot.com/2011/08/car-is-stuck-in-park-and-shift-will-not.html

---- Engine will not go out of park mode? http://technoanswers.blogspot.in/2012/02/2002-nissan-sentra-will-not-go-out-of.html ---- Car stuck in park? http://technoanswers.blogspot.in/2012/02/nissan-sentra-stuck-in-park.html ----- Car will not come out of Park?

http://howtobyme.blogspot.com/2011/11/car-will-not-come-out-of-park.html

-----
Automatic transmission will not go into high gear?

http://howtobyme.blogspot.com/2011/11/automatic-transmission-will-not-go-into.html
--- Car wont downshift sometimes?

http://schematicsdiagram.blogspot.com/2011/12/car-wont-downshift-sometimes.html
---- Transmission will shift into drive?

http://schematicsdiagram.blogspot.com/2011/12/buick-park-avenuetransmission-will.html
----- Auto wont shift from park? http://schematicsdiagram.blogspot.com/2011/12/ford-taurus-wont-shift-from-park.html ---- Car Transmission will not go into Park mode?

http://schematicsdiagram.blogspot.com/2011/12/car-transmission-will-no-go-into-park.html
----- Shift indicator directly goes to 2nd when key is turned ON?

http://schematicsdiagram.blogspot.com/2011/12/shift-indicator-directly-goes-to-2nd.html
---- Third gear missing and engine losing power?

http://schematicsdiagram.blogspot.com/2012/01/third-gear-missing-and-engine-losing.html
------- Vehicle has whining sound in gear?

http://technoanswers.blogspot.com/2012/01/chevrolet-silverado-has-whining-sound.html
----- Hard to shift gears on Manual transmission?

http://technoanswers.blogspot.com/2012/01/hard-to-shift-gears-on-manual.html
------ Car hard shift at slow speeds?

http://technoanswers.blogspot.com/2012/01/car-hard-shift-at-slow-speeds.html
--- Automatic transmission shift lever hard to move on cold mornings?

http://technoanswers.blogspot.com/2012/01/automatic-transmission-shift-lever-hard.html
------ Gear shifts hard?

http://schematicsdiagram.blogspot.in/2012/02/2000-nissan-maxima-shifts-hard.html
------- Vehicle noticed sluggish delayed shifts while driving?

http://schematicsdiagram.blogspot.in/2012/03/vehicle-noticed-sluggish-delayed-shifts.html

-------

This will help.

Thanks.

For gear shift issues and gear stuck issues,the help links are provided below. Click the link below to go through troubleshooting procedure:---- ---- Car will not move when in gear?

http://repairhelpcenter.blogspot.in/2012/02/car-will-not-move-when-in-gear.html ---- transmission sticks in first gear? http://technoanswers.blogspot.com/2012/01/mercedes-benz-transmission-sticks-in.html ----- Transmission not engaging in first gear? http://technoanswers.blogspot.com/2012/01/mercedes-benz-not-engaging-in-first.html ----- Vehicle only goes in First gear?

http://howtobyme.blogspot.com/2011/11/chrysler-pt-cruiser-only-goes-in-first.html

----

Car is stuck in park and the shift will not move?

http://howtobyme.blogspot.com/2011/08/car-is-stuck-in-park-and-shift-will-not.html

---- Engine will not go out of park mode? http://technoanswers.blogspot.in/2012/02/2002-nissan-sentra-will-not-go-out-of.html ---- Car stuck in park? http://technoanswers.blogspot.in/2012/02/nissan-sentra-stuck-in-park.html ----- Car will not come out of Park?

http://howtobyme.blogspot.com/2011/11/car-will-not-come-out-of-park.html

-----
Automatic transmission will not go into high gear?

http://howtobyme.blogspot.com/2011/11/automatic-transmission-will-not-go-into.html
--- Car wont downshift sometimes?

http://schematicsdiagram.blogspot.com/2011/12/car-wont-downshift-sometimes.html
---- Transmission will shift into drive?

http://schematicsdiagram.blogspot.com/2011/12/buick-park-avenuetransmission-will.html
----- Auto wont shift from park? http://schematicsdiagram.blogspot.com/2011/12/ford-taurus-wont-shift-from-park.html ---- Car Transmission will not go into Park mode?

http://schematicsdiagram.blogspot.com/2011/12/car-transmission-will-no-go-into-park.html
----- Shift indicator directly goes to 2nd when key is turned ON?

http://schematicsdiagram.blogspot.com/2011/12/shift-indicator-directly-goes-to-2nd.html
---- Third gear missing and engine losing power?

http://schematicsdiagram.blogspot.com/2012/01/third-gear-missing-and-engine-losing.html
------- Vehicle has whining sound in gear?

http://technoanswers.blogspot.com/2012/01/chevrolet-silverado-has-whining-sound.html
----- Hard to shift gears on Manual transmission?

http://technoanswers.blogspot.com/2012/01/hard-to-shift-gears-on-manual.html
------ Car hard shift at slow speeds?

http://technoanswers.blogspot.com/2012/01/car-hard-shift-at-slow-speeds.html
--- Automatic transmission shift lever hard to move on cold mornings?

http://technoanswers.blogspot.com/2012/01/automatic-transmission-shift-lever-hard.html
------ Gear shifts hard?

http://schematicsdiagram.blogspot.in/2012/02/2000-nissan-maxima-shifts-hard.html
------- Vehicle noticed sluggish delayed shifts while driving?

http://schematicsdiagram.blogspot.in/2012/03/vehicle-noticed-sluggish-delayed-shifts.html

-------

This will help.

Thanks.

For gear shift issues and gear stuck issues,the help links are provided below. Click the link below to go through troubleshooting procedure:---- ---- Car will not move when in gear?

http://repairhelpcenter.blogspot.in/2012/02/car-will-not-move-when-in-gear.html ---- transmission sticks in first gear? http://technoanswers.blogspot.com/2012/01/mercedes-benz-transmission-sticks-in.html ----- Transmission not engaging in first gear? http://technoanswers.blogspot.com/2012/01/mercedes-benz-not-engaging-in-first.html ----- Vehicle only goes in First gear?

http://howtobyme.blogspot.com/2011/11/chrysler-pt-cruiser-only-goes-in-first.html

----

Car is stuck in park and the shift will not move?

http://howtobyme.blogspot.com/2011/08/car-is-stuck-in-park-and-shift-will-not.html

---- Engine will not go out of park mode? http://technoanswers.blogspot.in/2012/02/2002-nissan-sentra-will-not-go-out-of.html ---- Car stuck in park? http://technoanswers.blogspot.in/2012/02/nissan-sentra-stuck-in-park.html ----- Car will not come out of Park?

http://howtobyme.blogspot.com/2011/11/car-will-not-come-out-of-park.html

-----
Automatic transmission will not go into high gear?

http://howtobyme.blogspot.com/2011/11/automatic-transmission-will-not-go-into.html
--- Car wont downshift sometimes?

http://schematicsdiagram.blogspot.com/2011/12/car-wont-downshift-sometimes.html
---- Transmission will shift into drive?

http://schematicsdiagram.blogspot.com/2011/12/buick-park-avenuetransmission-will.html
----- Auto wont shift from park? http://schematicsdiagram.blogspot.com/2011/12/ford-taurus-wont-shift-from-park.html ---- Car Transmission will not go into Park mode?

http://schematicsdiagram.blogspot.com/2011/12/car-transmission-will-no-go-into-park.html
----- Shift indicator directly goes to 2nd when key is turned ON?

http://schematicsdiagram.blogspot.com/2011/12/shift-indicator-directly-goes-to-2nd.html
---- Third gear missing and engine losing power?

http://schematicsdiagram.blogspot.com/2012/01/third-gear-missing-and-engine-losing.html
------- Vehicle has whining sound in gear?

http://technoanswers.blogspot.com/2012/01/chevrolet-silverado-has-whining-sound.html
----- Hard to shift gears on Manual transmission?

http://technoanswers.blogspot.com/2012/01/hard-to-shift-gears-on-manual.html
------ Car hard shift at slow speeds?

http://technoanswers.blogspot.com/2012/01/car-hard-shift-at-slow-speeds.html
--- Automatic transmission shift lever hard to move on cold mornings?

http://technoanswers.blogspot.com/2012/01/automatic-transmission-shift-lever-hard.html
------ Gear shifts hard?

http://schematicsdiagram.blogspot.in/2012/02/2000-nissan-maxima-shifts-hard.html
------- Vehicle noticed sluggish delayed shifts while driving?

http://schematicsdiagram.blogspot.in/2012/03/vehicle-noticed-sluggish-delayed-shifts.html

-------

This will help.

Thanks.

Manual or electronic t case?

Section 07-07: Transfer Case, 4x4 System, Service 1994 Bronco/Econoline/F-Series Workshop Manual
DESCRIPTION AND OPERATION Electronic Shift Operation The transfer case is equipped with a magnetic clutch, similar to an air conditioning compressor clutch, which is located inside the transfer case adjacent to the lockup collar. The clutch is used to spin up the front drive system from zero to vehicle speed in milliseconds. This spin-up allows the shift between 2-high and 4-high to be made at vehicle speeds listed in the vehicle owner's guide. The spin up engages the front lock hubs. When the transfer case rear and front output shafts reach synchronous speed, the spring-loaded lockup collar mechanically engages the mainshaft hub to the chain drive sprocket and the magnetic clutch is then deactivated. Shifts between 4-high and 4-low can only occur with the transmission safety switches closed. The vehicle's speed must also be within specified limits as determined by the transfer case speed sensor (3 mph or under). Electronic Shift Control System
This system consists of a two-switch control system, an electronic control module, an electric shift motor (7G360) with an integral shift position sensor, and a speed sensor. Switch Control System
There are two control switches located on the upper right corner of the instrument panel for fingertip shift control. The two switches are mounted horizontally and are identified as "4x4" and "LOW RANGE". Two indicator bar lamps are located in the instrument cluster.



When either of the two switches on the instrument panel control are depressed, the first thing that happens is that the electronic control module receives input from the transfer case shift position sensor to verify what position the transfer case is in (2H, 4H or 4L). Next, the electronic control module looks at the speed sensor and the park/neutral position switch or clutch pedal position switch (depending on transmission type). If all conditions are correct to allow the desired shift, the electronic control module will tell the electric shift motor to execute the shift. After the shift has been made and the electric shift motor is off, the control module again looks at the shift position sensor to make sure the proper shift has been accomplished. Finally, the dash indicator light and the pushbutton light on the control panel will be illuminated by a signal from the electronic control module indicating the desired function has been completed.
Electronic Control Module
The electronic control module, located on the passenger side, controls the operation of the transfer case in response to inputs to the pushbutton control by the vehicle operator, the speed sensor, shift position sensor and the park/neutral position switch. Speed Sensor
The speed sensor, mounted on the rear of the transfer case , tells the electronic control module the speed of the vehicle to allow range shifts (in or out of 4L) to occur. Shift Position Sensor
The shift position sensor, an integral part of the electric shift motor , tells the electronic control module the shift position of the transfer case . Electric Shift Motor
The electric shift motor , mounted externally at the rear of the transfer case , drives a rotary helical cam which moves the 2W-4W shift fork and 4H-4L reduction shift fork to the selected vehicle drive position.

the actuator on the diff might be stuck. I had a 97 sub and it felt funny when turning hard but turns out i had it in four high. make shure your in 2 high and change the diff lock selenoid

You can try several things. You can stop the vehicle as if you are going into low range and shift the high range 2h, 4h, etc.. Ford advertises the Electric button type as "shift on the fly" but does not say the gears are synchronized to do that with manual engagement.

Change the lube this time to see if the lube is Milky. There have been floods, otherwise the case is sealed whether you park it or drive it. You still could have rust on the shift linkage. You need to move the linkage as you spray it. Then the offbeat chance something was bent from offroading. A Salvage Yard is a wonderful place to learn how a car is built. You may see their part looks different than yours.

Well i guess check your vaccum lines. Is it always in 4x4 or can u switch out to rear. If so unlock it by putting it in reverse from 4 wheel to 2 wheel then go forward. Maybe you clogged the tranny maybe a flush might help what about the transfer case maybe it needs a good cleaning? just guesses