Outer Limits 4x4 Board

when in high 4 and low 4 transfer pops out of gear under any load. i heard from a mechanic theres a screw on the top of the box you can adjust or something like that, but just thought id ask here before playing around with things?
cheers

anyone got any ideas?

There is a rod that goes between the bottom of the high/low lever and a bracket on top of the transfer case. If this is not adjusted correctly then it can give you these problems. Undo the retaining nut on the end of the rod that mounts into the transfer case bracket (refer to pic below) and take that end of the rod out temporarily. By hand you should now be able to move that bracket side to side and each "position" will "click" into place. It has 3 positions - High, Neutral and Low.

Move it in the middle position (Neutral) and have someone hold the 4wd stick in the Neutral position from inside the cab. Now make sure that the bolt on the end of the rod you removed previously lines up perfectly with the hole in the bracket. If it's not a perfect line up (in that you need to pull the rod forward or back to get the bolt in the hole) then you have probably found your problem. Adjust the rod to suit and put it back together. If the rod lines up fine then you may have an internal transfer case problem.

Thing is though, it's unlikely that it would come out of adjustment on it's own. Has anything been done to the transfer or gearbox or levers prior to the problem occuring? Have you recently fitted a body lift?

cheers ray ill give that a look tomorow. there is no body lift

is the connection from the adjustable rod to the lever supposed to be loose??