Ok so when i put my truck into 4lo and tromp on it it pops out and if im real easy with it (which im not) it doesnt! Also it works fine in 4hi so im stumped any ideas out there on this would be much help thanks!!

 

Are you getting it all the way into 4lo? Might check the linkage adjustment, otherwise, you probably have an internal problem.

 

Yea its all the way in i unhooked the linkages and manually engaged it and it still pops out! this is my DD so i was curious to see if anybody had this problem before and new what internals were broke so i could order parts before o pull it apart!

 

It might be as simple as the little nylon guides on the end of the range fork have worn away...... (seems to be a common problem) Or, you might have busticated parts.... won't really know until you open it up, and look. Do you have a backup vehicle?

 

I had this same problem on my '87 Dodge Dakota, it turned out to be the linkage out of adjustment. The funny part was that it was only out of adjustment by about 1/16th of an inch where the shift lever contacted the 4-Lo stop.

I drove it for years like this (with it popping out of 4-Lo intermittently, didn't need 4-Lo much), until someone told me to adjust the linkage even though I thought it was within spec (close enough).

You might wanna try re-adjusting the linkage as accurately as possible. At least as a first step before dropping the t-case.

Cheers,
Chris

 

No thats the part that sucks this is my only truck and i know i can fix in an affternoon at my buddies shop if i have the parts there when i start! Thanks i think ill try replacing the nylon guides first. I assume i can do this with out busting the case in half? thanks again!

 

Nope, in order to get to the nylon guides, you MUST split the case. They are on the range shift fork after all, which is rather deep inside the case.

 

darn well ill makes sure i have those when i go to drop the case! hopefully thats it if not im bumin a ride from my buddies till my parts get in! thanks for all the help again

 

You are welcome.

If you have a nice shop to work in, with a hoist, and trans jack.... dropping the t-case really isn't that much of an ordeal. If you have a buddy to help you, it makes it even easier. Its a couple hour endeavor though, so, take your time, do it right, do it once. Don't worry about it again.

 

Since your beating on it all the time, you might want to look into getting a Transfer Case Saver. And btw, is the lever/transfer case actually popping out of 4x4? Or just the front axle?