dana 20 transfer case

[Amc71601]

I have a 76 cherokee with a d20 and when I get the rpm's up it pops out of 4wd into neutral and 4 hi pops out really easy should I pull it and swap it out with my spare or is it an easy fix?

[Stuka]

sounds like the intermediate shaft is worn.

[carrotman]

The 76 TSM give four possible causes and corrections:
1.front output shaft sliding gear disengaged from front output shaft gear-excessive end play, worn or bent shift fork.
2.main shaft gear disengaged from rear output shaft sliding gear-check torque on main shaft gear nut.
3.shift lever torsion spring not holding-replace torsion spring.
4.rear shift rod poppet spring not holding-replace poppet spring.

My friend's Bronco did the same thing. When 4-wheeling we would put a bungie cord around the stick to keep it in gear.

[Desert Beast]

mine does this, but bieing twin stick only the rear disengages. mine useto pop out of 2hi into neutral but the twin stick fixed that. just go for the bungie method should work.

[porkchop]

Sounds like the poppits and springs are worn. You can fix it on the truck.