Going down the road today my transfer case started popping out of gear, it did it three times. In less then 10 minutes then it didn't do it again. It did it around 50-65 mph. I really need my truck for work tomorrow anybody have any suggestions?

Toby

 

The ususal cause of popping out of gear is adjustment of the shift rod trunnion.

Jack the truck up on a set of jackstands, shift it to 2H, then loosen the trunnion bolt and center the shift rod on the trunnion with the transfer case in 2H. Work the shift lever on the side of the case to be sure it is really centered in 2H, then align the linkage with the selector, and tighten the trunnion nut to 90 inch pounds.

 

Thanks I'll try that, Does it have to be jacked up? It's tall enough I can get to it real easy.

 

Mine also popped out of gear when the shift rod was out of adjust or in my case was loose.

 

If you have enough room to work, you will not need jack stands.

 

If the adjustment is OK, and it still "pops" out of gear you will need to remove the T case, split it and inspect the shift forks. I often find one of them ground into the slider gear (for lack of more tech terms). Requires one shift fork, the gear it rides on, and a pump.