Swede

Has anyone come across the problem of having their Transfer Case popping or slipping out of 4HI back into 2HI?

At first I thought it may be pressure from my shifter boots being stretched out due to my BL but I still have the issue after relocating the boots further down the levers to the stock position so that can't be the cause. Is there a spring in there that gets weak by any chance? Thanks.

dropzone

iTrader: (6)

Did you enlarge the hole at all? just adjusting your boots will not solve this problem. The body of the truck is now raised and is vibrating with road movement/torque of the engine. and the selector lever at a closer distance to the hole while being at the same angle it was stock. Make sense? some people remove the lever and either cut and weld it at a different angle or elongate the hole.

Swede

It's not hitting the body as far as I can tell. There is at least 3/4" clearance while in 4Hi between the body and the lever at the closest point. It also pops out at the strangest times like when I'm driving down the highway at 90Kph or so.