Transfer linkage coming undone ?
 

1995 12V 5 speed 4x4. While driving down the road, there is a bolt that will come out of the transfer case. When this happens there is nothing as far as driveline power. We have tightened it up twice now, but it will keep backing out. Is there a fix for this or what can be done to keep this bolt in the case.

When the bolt comes out, its as if it goes into neutral (xfer case) and you have no power to the front or rear drive shafts and you are stuck along the road. Loctite, lockwashers ? Whats the fix? thanks

Something seriously wrong. The TC should not come out of engagement when the lever rod loosens up ( which it shouldn't do ).

Almost sounds like you need some internal TC work that would keep it from putting pressure on the shift lever?

I know I have driven mine with the lever clean out and the TC manually put in 2Hi.

I'd check for the snap ring on the output shaft, behind the tail housing (4 bolt part). If it's ever been pulled out and re-used it has a tendency to break, letting the shaft walk around and shift itself. If the ring is fine keep going and pull the transfer case! The detent ball and spring inside the case that holds the "rooster" comb in the selected gear is pretty strong, can't rembember if that is installed from the outside or not...good luck. edit: just looking at the diagram I think it's threaded from the bottom, #68.

Snap ring is #5 in diagram. What bolt is loosening?

http://www.drivetrain.com/images/sto...e/np241_lg.jpg