Dana 24 T-case popping out of gear

[1971ford]

Anyone ever had this issue?

I don't have any shift linkage on the transfer case right now because i haven't adapted it to fit the dodge transmission yet so i juts crawl under the truck for now.
I forgot the shift pattern so just moved the t-case bar in and out until it was not in low range and the driveshaft didn't spin. This is when the bar is pulled all the way out.

But now that I look at the shift pattern, all the way out would be 4HI, so why could I spin the driveshaft All other bar positions don't allow the truck to move (N) or puts it in low range (2LO or 4LO)

Now when I drive the truck, occasionally I'll be cruising and all of a sudden it starts revving up. Crawl under it, and the linkage has pushed into the t-case. Yank on it to pull it back out all the way and away I go.

Seems I have shenanigans going on here

Np205 swap in the future but for right now...

[averagef250]

Dana 24 has forks and sliders that engage the gears just like most transmissions, just no synchros of coarse.

Popping out of gear is usually a symptom of the sliders and dog teeth being hammered from abuse. Worn forks and sloppy bearings can cause it too, but you should notice a lot of play in the forks and gear whine from shot bearings.

[1971ford]

Interesting

It's still popping out of 2hi into N, got a ratchet strap on it now...

As for it not going into 4hi, i wasn't pulling the linkage out all the way, all gears work fine, just popping into N every once in a while. I'm guessing the shifter/linkage is enough friction to keep it from doing it, though.


But there is actually no gear whine at all that i can hear, and no play at all in the linkage.

[fomocoguy]

Are you trying to hear it over an open exhaust pipe?

[1971ford]

yeah over an open cummins turbo

Which is really not loud at all. But my cab is sealed real tight and sound deadened all over, so that also may help block out any t-case noise

[davesoehren]

i have a 1970 f250 with a dana 24 and it was stock...it is doing the same thing... when i step on the gas a little too much it pops out of 2h in to N and it grinds a little like it didn't go all the way out...it is now doing it in 4H...from 4H into 2H then to N...i adjusted the linkage but it still dose it...what might be the problem

[1971ford]

Mine still does it allllll the time, I just threw a ratchet strap on it and called it a day. Doesn't pop out anymore.. but not a fan of having a ghetto strap under my truck.
NP205 soon to come, not going to bother pulling the d24 turd apart. THe scrap pile doesn't care if it pops out of gear.

[Manny]

Mine still does it allllll the time, I just threw a ratchet strap on it and called it a day. Doesn't pop out anymore.. but not a fan of having a ghetto strap under my truck.
NP205 soon to come, not going to bother pulling the d24 turd apart. THe scrap pile doesn't care if it pops out of gear.

If you are going to scrap the dana 24 send it my way......... Just thinking i am gonna keep mine is all and rebuild it seems to be hated by most though