Need ideas - 4WD problems

[BigTreesFJ60]

My rig pops out of 4h after very little time engaged. This started last winter and I replaced the detent ball and spring which fixed the problem for a short time. But, now it's back. Any thoughts on what to check next?

Thank you, winter is coming!

 

[mano002]

Is the rest of your shift linkage tight? Mine was loose and would pop out of 4x4 all of the time.

 

[BigTreesFJ60]

How do I check it? Just try and wiggle the linkage?

 

[mano002]

Pretty much, crawl under it and have someone wiggle the shifter. I had to tighten a couple nuts and add a washer behind a cotter pin to tighten things up.

 

[Cruzerman]

I had a rig that did this and I didn't want to deal with it and so I used a bungee cord to "fix" my issue. Worked for years until I got rid of that rig. May not be the best solution, but I was young and broke.

 

[DFXR]

How's your driver's side motor mount? If your (trans) shifter moves to the right under load (think taking off in first gear) then there's a good chance that your motor mount is toast. That movement will pop your t-case out of 4WD as well.

I had the same thing happening, and even replaced the detent balls and springs like you, before replacing the motor mount. That fixed it.

The catch is that the mount will not look broken when you're just crawling around under the truck. it's like a sandwich that separates in the middle.

Aftermarket are around $40 from @cruiseroutfitters and OEM are more like $75. Some guys just replace the mount with a permanent bolt.

 

[OSS]

There's a good chance that the front drive engagement teeth inside the transfer have rounded off their normally square edges. If the teeth get rounded enough, they can't maintain a grip and the gear pops out.

Remedy: replace the transfer front output shaft and transfer front hub clutch (official name).