My 1996 H1 has developed a really annoying problem. The 4x4 transfer case kicks out of gear when it's in either 4H or 4HL. It kicks out to neutral, and I have to put the tranny into neutral, shift the transfer case into 4L, then back to 4H, to get it going again. The problem has been getting worse recently, and yesterday it got really, really bad -- I couldn't go more than a mile or so between problems.

Obviously it needs to go in for work, but I'm hoping this is a known issue and/or that knowledgeable people here can give me some pointers so I know what I'm talking about at the shop. Any ideas?

 

My best guess without seeing the problem first-hand is that the plastic shift fork pads in the t-case are probably worn out; the only way to fix that problem is to take apart the t-case and replace them.

If you are not up to the task of doing a rebuild yourself, you are looking at paying a garage for a rebuild (or replacing it with a freshly reman'd t-case and returning yours as a core).

You will probably want to replace the chain while you are in there, too; you can get a complete rebuild kit like this one:
http://breggin-enterprises.stores.ya...trcarekit.html and do it all at once.

Or, you can just source the parts yourself...

 

I have never had that issue before. Had lots of others but not that one. Manny's suggestion makes sense.

 

Ugh. Well, thanks for the very plausible theory.

Anyone got a H1-friendly shop in the Seattle area to recommend?

 

Not me but someone should chime in shortly.