I started a 6hr drive last friday and 30 min into the drive my transfer case started popping into neutral ( 3or4 times). I was pulling a empty 18ft trailer. 

I swapped the trailer with a friend that was headed the same way, drove my truck back to the house and it did the same thing twice. So I had to hold the transfer case knob the rest of the way home.

 

Any Ideas on were to start? (Right now I have a bungee cord hold light tension on the shifter)

 

 

I had few older np205,203,200 apart and if memory serves me well, in that case it was ether ring maybe called clutch, with worn teef, fork bent or badly worn, sometimes has plastic clips that wear out, keeping it from fully engaging, or gear itself has wore out teef, from grinding when shifting. 

I haven't looked to close at newer ones, sorry.  Hopefully it's something simple, but sounds like internal issue. 

Just a note out of all the np t cases I went through, very few needed hardly anything but seals, and a bearing sometimes. And we abused the crap out of them with high RPM and huge tires, with minimal damage. I made em all in a tween stick setup, where front and rear was independent from each other, rather simple. 

I found a reman for $1000. 24mo/24,000 miles.

WAY cheaper to rebuild.  your issue is likely something VERY simple.  i'd try to R&R
 

 

Do you have a 241dhd or dld? This is a great article on the dhd

 

8 hours ago, BBHD said:

Do you have a 241dhd or dld? This is a great article on the dhd

 

 

Np241dhd