FAQ4005 1992-1993 Dodge NP205 Transfer Case Jumps Out of Gear

Problem: 1992-1993 Dodge NP205 Transfer Case Jumps Out of Gear

Possible Causes (Note: There may be a combination of issues listed below causing the problem):

A) Shift Lever Hits Gate before Transfer Case is Fully Engaged: Adjust Brackets (See Photo Above)
B) Clutch Teeth on Selected NP205 Gear and Sliding Clutch Ring are Worn: Rebuild Case and Replace Worn Parts*
C) Transfer Case Shift Fork tips are worn down: Replace QU50338 Fork(s)
D) Poppet Spring(s) are Weak: Replace QU50252 Springs
E) Shift Rod Worn: Repair or Replace QU20149U Rod
F) Hole in Transfer Case Shift Link is Worn Oversize: Replace with New QU10870 Link
G) Pins that attach Shift Link to Shift Rods Worn: Replace with QK2017 Pin Set
H) Transfer Case Shifts Hard Causing Excessive Transfer Case Shifter Bracket Flex: Rebuild Transfer Case**

*Inspect and Replace Worn Parts:
TK10859U Used Low Gear
TK20107U Used High Gear
QU50339 Sliding Clutch Ring
TK20124 New or TK20124U Used Idler Gear

**Transfer Case Rebuild Kits:
TK2011 23 Spline Master Overhaul Kit
TK2000 29 Spline Master Overhaul Kit