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Ok.. Driving to work this morning the rpms drop? And the truck (the 84 Bronco XLT) clunks and then goes again. Seems like the Xfer slipped into neutral.
Coming home from work it did it every 2-3 miles.. I had to shut the truck off... put the xfer in 4L, then put in 2H and it was fine... the slips out... nasty sounds... shut truck off.. etc..
What could be the problem? I definitely think my Xfer is toast!
In 2H and 4H it still pops out on the Highway... It was a quart low on dexron tranny fluid.. though I don't think that would effect it that much.. I am going to drive it now and see if it still slips.. I think it will...
A transfer case has 2 shift forks, Hi/Lo and 2WD/4WD. I believe your problem is with the Hi/Lo fork. I have seen several of these forks worn to the point that it won't push the hub far enough to engage High gear completely. The hub has a taper on the teeth to make it easier to shift, that taper will push the hub back against the fork and into neutral if the fork is worn.
Both the Shift fork and the range fork were junk as well as a stretched chain... I got it rebuilt.... $800 all said and done... 18month/18,000 waranty...