Early 70’s Ford Truck w/Dana 20 Xfer case
The problem is that when I put the truck in 4W Low, it will sometimes slip out of gear into 4W Neutral. It happens more often when climbing hills than driving on level ground. It hasn’t ever slipped out of 4W High. It is drivable the way it is, but it’s annoying. If there were an easy fix I’d do it. If I have to remove the xfer case, that seems like a big job, so probably not. What do you think?
The manual suggests these four as possible reasons
Shifting poppet spring weak.
Bearing broken or worn.
Shifting fork bent.
Improper control rod adjustment.
Which is the most likely problem? What is the “poppet” for and where is it located? Can anything be done to diagnose or fix this problem w/out removing the xfer case from the vehicle? What about the control rod? Can it be adjusted with the xfer case installed? If so, where is that adjusted?