transfer case popping out of 2HI

[Kyle]

Just recently got my 1949 cj3a driving under its own power reliably but if sometimes pops out of 2wd Hi range.  4wd Low is awesome for around the house and woods but would like to know if a total rebuild is usually required or if it can be fixed in the jeep?  Could it just be the enormous amount of crud built up on the shift rails preventing everything from staying in gear?

[BillT]

I would start with the easy stuff first. Clean up the shift rails. Then see what  happens. Make sure the springs, for lack of the proper name, are there and in good shape. There is one each attached to the shift canes at the rod.

[athawk11]

Here is the official Willys Service Bulletin describing the symptom and the potential cures.� You may get lucky with one or two of these fixes, but ultimately I found that the T90 transmission will need of a few parts or a well placed shim to eliminate this issue.�

[Rus Curtis]

Kyle,
You mention only 2WD high.  Does it pop out in 4WD high? 

I had to go into my transfer case to replace some thrust washers.  I also replaced the seals on the front shaft cap (around the shift rods) but didn't do anything else to that part.  I think there's some poppets held in by plugs to keep the shift rods in place.  When you're down there cleaning, you may want to check to ensure the plugs are in place.  If one is missing, it may explain why the transfer won't stay in high.

[athawk11]

I did misread your issue.� 2ND gear pop out on the transmission is quite common.� � So, the TC High-Low shift cane is slipping back in to neutral...correct?� If so, I would remove the poppet plug on that side of the case and check for a broken spring...as others have suggested.

[Kyle]

My tub might be hitting it also?  As the tub sits low onto the transmission when I took off my transmission tunnel cover.  I think I was in 4wd high when I kept coming out on me.  I will test drive again tomorrow.  Watched a few Dana 18 rebuild videos on youtube, not sure I am ready for all that just yet.  Jeep has sat since the early 90s it was my great uncles he is gone now so I can't ask if it was doing that then...

[Rus Curtis]

My tub might be hitting it also?� As the tub sits low onto the transmission when I took off my transmission tunnel cover.� I think I was in 4wd high when I kept coming out on me.� I will test drive again tomorrow.....

Checking interference should be pretty easy.  Shift to high and crawl under to see if it's touching.

Using stock thickness Body Sill Liners, my tub edge is right next to the top edge of the transmission.  I've never seen a large space gap between the two.