I have a '93 3/4 ton pickup with 6.5L TD, 5 speed trans and the transfer case jumps out of gear when you let off the throttle. Sometimes violently. It seems to happen more frequently at higher speeds. I'm assuming the trans case needs rebuilt. What model is the transfer case? Where is the best place to get a kit? I am fairly mechanically inclined, and I would like to do this myself. Are there any special tools needed?

Thanks in advance for any help.


This is also posted in the Ask The Techs section.

Had similar problem in '87...left truck in park on a hill, came back out of store an truck was across road. Turned out the transfer case "fell" into neutral because the shift fork was worn out and the gear fell out. You could pull the shifter back and re-engage the fork and gear but you never knew when it would fall out. IIRC the fork was around $70, fairly easy to fix, need to drop case and split it apart. Just be careful ball bearings fall out and go everywhere!
Good luck

Mike

Slaphappy i had a 86'that did same thing and it turned out that the linkage was all full of dirt and rust and it would'nt engage completly.Just something to check you never know.

Thanks for the input guys. I'll check it out this afternoon.

Shift Fork.........

Happened on my 1987.........

Good Luck,

T:cool: NY

I'm under the impression that this is a NP241 transfer case. Is that correct?

There should be a round tag on the t/c that states model. Just split the case and take a quick look, you will probably find a bad shift fork. Check your oil pump also, since shift forks usually fail from lack of lube.:grd:

Remove the output housing and look at the broken snap ring that hold the main shaft. Replace and drive. Total bolts 8, total cost, less the 5 bucks, total time. less then one hour