I have noticed that my 96 now pops out of 4 Hi while driving. It doesn't pop with any force, so perhaps I should say "slips" out of 4 Hi. I can put it in 4 Hi at up to 40 mph (should I be able to do it any faster?), and it stays for a while, then later I will notice that the 4wd light is no longer on, and when I reach down I feel that the shifter has gone back all the way forward. I never feel it come out of 4 Hi. I have watched it closely when coasting and when accelerating, even hard acceleration, and it stays in fine, until I stop watching it.
I pulled the entire tranny and t-case out back in the summer to install a new TC, and put it back in. I have changed no adjustments, if there are any, on the shifter for the t-case.
Is there and adjustment I should be looking at? What else should I check out?

It does grind if I am going over 40 mph and try to go into 4 Hi. My 99 can do this at 50+, but the 99 has a different t-case, an HD, while this one seems to have the LD t-case (going by th elakc of a PTO plate on the side of the t-case).

Ideas appreciated.

Thanks,
Chris

 

it is going to have a bad shift fork inside(worn down).

 

So the bad shift fork is causing this? What does it take to replace it? Can I get that part someplace besides the dealer? How much will I be spending? Will I have to pull the t-case to replace it, or can it be done in the truck?

Thanks,
Chris

 

My problem started when I ran a spare that was numerically the same size, but wasn't the same size - driving on variable roads (snow/ice/dry) in 4wd caused stress on the transfer case and the result was the big snap ring that holds the gears on the main shaft was forced off. The bad news is that even though I replaced the snap ring several times, it would not stay in place and I think I damaged/tweeked the case. I ended up getting another transfer case to fix it for good.

Hope this helps,

Pat

 

there is an adjustment on the t-case shifter linkage you may not be going all the way into gear. Often the fork is bent but try that first. there is a company that sells a fix for the snap ring that has two pieces that bolt together in place of the snap ring. Its called Gillys transfer case saver $39.29 Its a good thing to have if the snap ring comes off it can mess up the gears in the case often the first time it happens. good luck

 

i would pull the t-case 1st, and tear it down see what is wrong. any transmission shop can get u the parts.