96 K1500, T-case pops into neutral in 2wd, works in 4wd, but with no 4wd.

[Sweet35th]

Ok heres the deal, 96 K1500 suburban with 150k on it. While driving in 2wd the t-case sudenly popped into neutral. Pushing the 4wd button the Tcase shifted into 4wd, engaged the front axle, and worked fine. Shift back into 2wd and it was ok for a lil bit, but under higher load popped back into netraul.

So I just left it in 4wd to get the truck home. In the mean time the 4wd light began to flash, and the front axle would no longer stay engaged. So basicaly now I have a truck that is netrual in 2wd, and 2wd when in 4wd

To add, under heavy load in reverse the Tcase will also pop into neutral.

I have 2 theorys as to why, but I am a Ford technician and have never had one of these t-cases apart.

Theory 1. The shift actuator motor is not making full travel. Only partialy engaging into 2wd, under load kicking netraul.

Theory 2. The shift ford in the T-case (do they use shift forks?) is damaged/worn, making is to the the colar only partialy engages/disengages.

I have found the shift motors for $150 on ebay, but would rather try to find one at a local auto parts store.

Im not afraid to take a $150 gamble and try the shift motor, but only if there is a possibility that this is causing it.

Any input???

[2000CAYukon]

http://www.drivetrain.com/gillies/Tcasesaver.html

Do a search on casesaver and you will see all the post on this subject.

//2000CAYukon

[Sweet35th]

Thanks for the link. I looked, and it apears that the broken snap ring causes mostly pump related issues. My fluid still looks beatifull, if there was a pump issue, it would most likely be burnt.

[2000CAYukon]

A broken snap ring will cause popping and grinding noise. Not sure about popping into neutral.

Sounds like you may be having tranny problems if the rear wheels are not working.

Which Transfer case do you have?

//2000CAYukon

[Sweet35th]

Originally Posted by 2000CAYukon

A broken snap ring will cause popping and grinding noise. Not sure about popping into neutral.

Sounds like you may be having tranny problems if the rear wheels are not working.

Which Transfer case do you have?

//2000CAYukon

Its deffinatly a t-case issue. The tranny is working fine. When in 4wd, it is the rear wheels driving the vehicle, the front axle is no longer engaging, most likely because the 4wd modual is now seeing an error.