A couple of drivetrain issues with the truck

[bfourman]

I posted this over on the other "place" but I figured I should post it here as well to get some other opinions.

96 K2500 "F" code NV4500. Clutch replaced ~5k ago by PO.

The other day as I was turning a corner and letting the clutch out, the transfer case popped into neutral. I didn't think much of it, maybe I had bumped it getting in or out somehow. A couple blocks later, this time going in a straight line under slight acceleration, it did it again. Got it home without any other problems.

Next day it did it again under similar circumstances. The next time I stopped at a light, I couldn't get the truck into gear unless I shut it off. Same thing when I went to shift into 2nd (3rd on the stick). Nursed it to my shop and drove the Jeep home.

Swapped the master cylinder, we completely bled the clutch, and all was well for a bit. Now everything works fine until I drive ~10-15 minutes, then the t'case will pop into neutral upon a 1st (2nd) gear start. Once it does that, I have to pump the clutch a couple times to get it to shift. It will be fine for another couple miles, then pop out upon another dead start.

Ideas?

Also, I still have 5th.

 

[bison]

T-case Issues

 

[tanman_2006]

Samething is wrong with my 94. The shift forks are worn.

 

[bfourman]

T'case shift forks or trans?

 

[bison]

T-case

 

[tanman_2006]

T-Case. I haven't got the chance to tear into mine but it didn't sound to complicated. Might not be terribly expensive either.

 

[6.2 turbo]

It could be the snap ring on the main shaft,this is inside the rear tail housing and can be fixed on the vehicle,Ive seen a few broken ones,Sonex makes a kit to eliminate this problem. An easy way to check is to remove the rear drive shaft and then check the output shaft for in and out play,it will be very obvious . All the ones I saw broken had one piece drive shafts,and under a hard launch it would sound like grinding gears,since everything is moving inside,possibly trying to shift into 4 high,which in your case might also move the shifter.

 

[tanman_2006]

Haven't heard that one but my 94 comes out of 2hi and into N everytime I let out on the throttle. Same happens in both 4hi and 4 low. 4hi was the 1st to go since it was used the most then we used 4 low instead.

 

[6.2 turbo]

I don't know if the snap ring is your problem,but it's something thats easy to check,the main shaft will move probably 1/2 of an inch or so .

 

[bfourman]

I'll look into that, thanks. I've rebuilt several transfer cases, so it shouldn't be a big deal.

I have a 2 piece driveshaft, but I will check the output shaft endplay also.