T-case randomly jumps into neutral

[Quadrdr77]

I have an 02 3500 with nv5600 and just recently the transfer case will randomly jump into neutral while driving down the road or it will make a clunk like it's going to and not do nothing. It doesn't do it all the time just when I'm driving around 70 with the cruise set. Any speed lower it doesn't do it and I can run the hell outta the truck and nothin happens. Just looking for ideas before I have to pay the local shop $900-$1300 to rebuild the whole thing. Tranny is a blue menthal with billet shafts with 3,000 miles on it. Any ideas or past experince with this is greatly appreciated.

 

[Mo Smoke]

Broken shift fork ?

 

[kazairl]

I had something similar happen. The splines on the input shaft and the locking shaft(that locks to the input shaft or the carrier) where partially sheared. However when it did that it would pop into neutral and then slam back into gear. Made a heck of a racket. Ended up breaking the shift collar and fork.

However it never did it to me just driving down the road. It didn't start doing it until after i pulled a fairly heavy trailer with it. I'm guessing the damage was already there but it didn't manifest itself until I was pulling a trailer.

Fwiw if it comes down to rebuilding it, you can do it yourself for around 400 or so depending on what you have to replace. T-cases are pretty simple.

 

[BigDctd]

yep mine did it. it was a few tore up thing inside! it will have to be rebuilt

 

[powerchoke-eatr]

The rooster tail or whatever you wanna call it broke in mine and it did the same thing. And would get locked into 4 low and wouldn't let it come back without taking the spring out of it to release it.