Engine/Transmission (1998.5 - 2002) transfer case poping into neutral

[moremph]

A friend of mine called me today saying his 02 3500 5600 transfer case has popped into neutral on him a couple times in the last few days and he is worried his transfer case is shot. Any ideas on what this could be ??? Thanks Travis

 

[Duluth Diesel]

The NV5600 is a transmission, not a transfer case. Are you having problems with the transmission or the transfer case?

 

[MTucker]

My 03 also will kick out of gear on a down hill run with my foot off the go juice, I have learned to deal with it by putting it in 4HI or giving it a little fuel. Another membewr ? from oregon had same problem and his dealer found some parts that were miss milled new that weree replaced that fixed it. I tried to contact him to find what dealer he went to but didnt here back from him. Keep us posted thanks Mike

 

[moremph]

Transfer Case not the transmission i was just saying it had a nv5600 transmission in it. You are putting up with an 03 slippin out of gear!!!!! Travis

 

[MTucker]

I had one dealer check it but couldnt get it to drop out on a short test drive,soo im dealing with it till it goes out completly or I find a dealer thats familiar with the fix I dont trust most dealers. Ive got about 26k on it, except for this problem its been a great truck, I get about 18 mpg in this hilly country. truck build date was 9/02 I dont if its the same defect as your friends . Mike

 

[robertyoke]

Originally posted by MTuker

I had one dealer check it but couldn't get it to drop out on a short test drive,



my 98 truck did that popping out of gear crap only down steep grade and only with a trailer or loaded,2 dealers said they could not duplicate problem so I videotaped it and took tape to dealer and they put new t-case in it.

 

[AGibson]

Having rebuilt my Transfer Case (241DHD)I can suggest a couple of things. You don't appear to have enough mile to have a gear wear problem. With high mileage the gears will wear at a slight angle and under extreme pressure pop out/apart. Inside your Transfer Case there are two forks held apart by a spring. One fork is fixed (allen screw) but adjustable on a shaft. The other is floating (slides) on the same shaft. The forks engage and disengage the gears. If the adjustable fork is off the gears clusters will not fully engage. Also the forks have plastic guides/shims that wear causing a possible adjustment problem. The adjustable fork has replaceable guides/shims. The floating fork does not. The forks are moved by a stepped gear plate and tends to lock in place (no slop) once shifted into position. Hope this helps!

Alan