05 Silverado 1500 popping out of 4wd

[Wgibby34]

2005 Silverado 1500 disengages out of 4hi. I’ve searched forums and only find were people have issue with trucks engaging into 4wd while in 2wd. Mine is the opposite. I live in Alaska so during winter time 4wd is used very often. Last year I changed front axle actuator and that obviously didn’t fix it. It will make a couple popping noises then goes into 2wd. Any ideas?

[richard wysong]

Broken shift forks in the transfer case

[Wgibby34]

Ok thanks. I was really hoping it wasn’t the transfer case. I will look into that!

just weird it will stay in 4wd in mild condition. Just kicks out under stress

[Wgibby34]

So I found a used one in town to hopefully get me through the winter. Going to remove mine and rebuild it with my son. Once I got it out I noticed JB weld so obviously someone tried to fix the common pin hole leaks at one time. So will replace rear outer housing. 

[Wgibby34]

So it wasn’t the T-Case. I ended installing a Zumbrota t-case and we had first snow since install and truck has same issue. At about 20 mph same popping/clunking noise and was try to disengage out of 4wd. Could it be splines on front drive shaft? I fell noise right under my feet. Thanks

[richard wysong]

Could be the front axle actuator isn't fully extending due to corrosion around the threads

[davester]

Do you have electric-shift or manual TC?  And do it have hte 'auto' setting, or just a regular 2 speed TC?