Transfer case popping out of gear !

[jimnance]

When going down steep grades with my trailer in tow my transfer case is popping into neutral. This requires a full step before it can be put back into gear. This happens only when the exhaust brake is engaged.



So far the dealer has been unable to duplicate the problem and unwilling to take the 1-1/2 hour round trip drive to the nearest big mountain so I can demonstrate.



Today, I called the dealer again in frustration. They now have ANOTHER '03 6 speed with the same problem. Dodge does not have a TSB for this problem, but they are going to look more carefully at the problem now that they have two trucks with the same problem.



I'm guessing that many other trucks could be affected, but do not know of the problem because they are not towing heavy loads and using an exhaust brake.



FYI

 

[Mopar_Mudder]

Electronic or Manual? My electronic has never given me any problems, never heard of any problems for that mater.

 

[jimnance]

MANUAL TRANSFER CASE. I'M SURPRISED TOO.



BEST GUESS IS THAT THE REVERSE LOADING OF THE GEARS BY THE ENGINE BACK PRESSURE IS PUSHING ON THE SHIFT FORK. I CAN FEEL IT ROCKING BACK AND FORTH AS I DESCEND DOWN THE HILL.

 

[Mopar_Mudder]

And everyone was worried about the electronic ones, go figure

 

[robertyoke]

you got a bad one

had same problem on my '98 3500 . took to three dealers they said they could not duplicate problem so ... ... can't help you . after lots of:-{} I video taped lever popping out of gear . also taped %grade sign on road & trailer pulled. with that proof they replaced transfer case under warranty. good luck !

 

[MTucker]

t-case problem

I have the same problem but mine kicks out on any steep grade when off the throtle. I took it to a dealer and couldnt get it to kick out. So on any incline I put it in 4hi and it doesnt kick out. If you find the cause please let us know. 03 6spd had problem since new 12k on it now ,other than this its been a great truck thanks mike

 

[SRadke]

Mine popped out on me once. Like you said, manual box, steep grade, and trailer in tow. The only diffrence was I had not yet engaged the exhaust brake. It has only done it once but if it happens again you can bet there will be a little :-{}



You can get it back in before a complete stop but you have to match the engine rpm to your ground speed in whatever gear you're in.

-Scott

 

[jimnance]

I called the dealer after having it pop out three times going through the Mountains North of Redding, CA.



After going down one particularly steep grade in neutral I called the Service manger on my cell phone. I told him I was fearing for my life.



Well, they consulted with Dodge and are ordering some part of the linkage in the top housing. Said if clearance exceeded . 030" on the part it could slip out of gear.



The parts are back ordered so they can't do the fix for two weeks.



If it works I'll post the details on the service order here for others to see.



If they could diagnose this over the phone with Dodge it's a problem that they have seen before.