When in 4wd the transfer case wants to pop out of 4wd, it's so bad i have to tie the shifter to the seat. Ive checked the nose and it's bolted on tight. Just started last time off-roaded, at first i could just shift it back and it would stay for quite awhile now as soon as there is a load it pops.
I had this problem on my FJ40 and it turned out to be a worn high-low shift fork. It was fixed by a new shift fork and t-case rebuild. I have heard worn motor mounts can cause the sae thing. The transfer case shifter has an adjuster on it, but I don't know how that would get out of adjustment.
Also look at the shift collar in the front output and the condition of the splines. I've seen worn splines bad enough to push the collar right out of engagement.
