Transfer Case

[jeepit]

T Case has gone out again. Case slips out of gear A couple months ago there was a loud bang. Now last week it did the same and popped out of gear. I came to a complete stop and shiftted back in 2HI.
The same thing happened 2 years ago and the collar had broken off so the shift fork was just slipping off it.
Now I am thinking that something else is causing this to happen.

 

[Ozymandias]

Is your T-Case still un-opened OEM or was it rebuilt in the past?

Because the shift fork DO NOT hold the gear once it is in, holding the gear does the main shaft together with the gear.
The fork is solely for shifting.

You have the 241 DHD right?

 

[jeepit]

No. 2 years ago it was repaired for the same problem.

 

[JMcCoy]

Is the shifter popping out? If not, it may be your CAD, not your T-case. Mine used to do the same thing.

1st time it started doing it, I replaced the vacuum actuator and it fixed the problem. I noticed there was water in the diaphragm.

2nd time it happened again several years later, I just pulled the diaphragm and drained the water out. Probably sucked water in the dry rotted lines.

3rd time, again years later, the rubber connector at the vacuum pump was dry rotted and wasn't pulling enough vacuum to keep the axle fully engaged.

Replaced CAD with a Posi-loc and later a solid axle. Problem solved.

 

[Ozymandias]

No. 2 years ago it was repaired for the same problem.

Which parts have been replaced back then?

 

[jeepit]

Which parts have been replaced back then?

Range shift collar broke off not allowing high range. So, that and shift fork were replaced.