Transfer case pops out of low transfer (1 Viewer)

[SciroccoDamonte]

This is an issue i inherited from the previous owner, the transfer case on my 91' pops out of low transfer, and ive been using a bungee cord to hold it in. The previous owner is a friend and he mentioned he did some extensive research into the issue and came to the conclusion it has something to do with the detent spring in the transfer case that locks it in position. It holds in high just fine. I have no problem just using the bungee cord but if theres a simple fix then id like to know it. Anyone else with this issue?

Is it worth fixing? ive also been considering going to a part time kit and in that case should I just get a part time transfer case instead?

 

[CharlieS]

Adjust the linkage.

 

[jonheld]

The transfer case linkage should have more range of motion than the shift arm on the transfer case.
If you disconnect the linkage (very quick and easy), the lever in the cab should flop around easily.
You should be able to manually move the high/low shift arm on the transfer case by hand and feel each detent as it snaps into position.

A body lift or very worn body mount bushings can also affect the linkage movement.

 

[SciroccoDamonte]

The transfer case linkage should have more range of motion than the shift arm on the transfer case.
If you disconnect the linkage (very quick and easy), the lever in the cab should flop around easily.
You should be able to manually move the high/low shift arm on the transfer case by hand and feel each detent as it snaps into position.

A body lift or very worn body mount bushings can also affect the linkage movement.

Thank you for the reply, I hadn’t thought of this and I will be trying this out. Thank you

 

[Izeloz]

What they said. I did a 1" body lift with a tcase extension, and I had the same problem after the body lift with it popping out. Unfortunately, I was in the middle of a trail in Moab when it happened, but the linkage is easy to adjust with basic tools, so it wasn't too big a deal.