My wife basically had that exact same thing last year. She was in the hospital for 12 days. Every thing was ok after. Hope he can have the same outcome.
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I'm not really sure why it was popping out, but it was also grinding gears trying to go back in ( clutch? ). I had met Jason from Redline and he thought the popping out of gear was a shim problem ( preload ) and that might very well be as I can't remember putting any in. Anyway going to start over with a different one and a different clutch.
Update on the trip... after we left the Tent Rocks all hell broke loose, the weather, the wagon and our Son had to have emergency gall bladder surgery. The surgery went bad and he had to be shipped to St. Louis for another surgery to fix the screwed up first one, leaking bile. He is having that done in the morning, so needless to say my Wife wanted to get home. I drove straight threw from New Mexico. Rain followed us the whole way, somewhere along the way my Wife says " you better turn on the wipers " and I thought they are on, her wiper was gone, laying on the hood with the gear stripped out, I drove all the way home with one wiper. Close to 20 hours straight, we're home and I'm drinking a couple of well deserved beers, 3am in the morning.
Update on Son, doing fine. They found the screw up and repaired it, he's comfortable and out of pain, should go home in a day or two.
Thanks Everyone for your concerns and prayers.
Time for a redo, headed out to Georg in Ca. he's rebuilding the transfer case with 4 to 1 low gear and all new parts. The transfer has been the only piece that was questionable when I rebuilt it, so I'm having a pro do it this time. This is going to get close to the Pig Party timing. I'm figuring @ a month to get it back here, doesn't leave me much time. All I can do is go for it.
Kind of wishing I took up golf, instead!
Golf is a lot more frustrating.