transfer case

[Beansie]

I posted yesterday when I shifted my 03 2500 5.9 5 speed manual into gear It made a grinding noise and popped then wouldn't move. Come to find out that grinding and popping was the transfer case being pushed into neutral. Why would that happen. Is the linkage that close. It just had a new transfer case put on it. Wondering if it was a fluke thing or something more serious.

 

[Fast69Mopar]

I would check the detent spring and the steel ball to make sure the spring is not broken. If the spring is broken it will not hold enough pressure on the shift detent and the transfer case can "pop" out of gear and into neutral.

 

[Fast69Mopar]

I would check the detent spring and detent ball for the transfer case shifter to make sure the spring is not broken or collapsed. If the spring is worn or damaged in any way it can allow the transfer case shift mechanism to move because the spring is not holding enough pressure on the detent gate.

 

[Beansie]

I was just driving down the highway about 60 mph and the thing tried to shift into neutral again. What the hell.

 

[Fast69Mopar]

Here is what I would do...

Set the parking brake and chock the wheels.

Get under the truck and disconnect the shift linkage for the transfer case.

Operate the shift mechanism on the side of the transfer case by hand and feel how hard or easy it is to shift the transfer case into each position.

Pay close attention to how it feels when clicking the detent from 2-HI
into 4-HI and then 4-HI to Neutral.

Each click should feel the same when moving the shift lever on the transfer case. It should be a very positive stop when the detent ball is pushed into the valley of each position.