Anyone else had that problem? It did not do this before the gear install. I even shimmed the detent ball springs with some washers so they were really tight. Now it just pops out of gear in 2wd on the highway sometimes. Real PITA since it is un-syncroed, and I have to nearly stop to get it to go back in.

Thanks,
Phil

Sounds like the clutch gear 'worming' off which is usually due to too much play in the shaft/s.
Give the rear output yoke a giggle.
It should move some ... but not a whole lot ...

P.S.
Are you SURE your linkage is fully engaging 2WD?
Did you do a body lift or TC drop at the same time?

Mine only pops out of gear when i'm off road on low range going down steep hills, but I have been told that is was normal:confused:

Thanks, I will check the shaft end play [insert beavis & Butthead joke here]

Body lift has been on the TJ for a long time, and I have a raised t-case.

Phil

what about linkage? Are you sure its going all the way into 4wd??

Originally posted by JasonTJ
Mine only pops out of gear when i'm off road on low range going down steep hills, but I have been told that is was normal:confused:

I don't think that's "normal".
I'd say that was intolerable and fix it.
I've two D300 Tera Low installs, a 3 gear and a 5 gear.
Neither pops out ... even going down the steepest Chokecherry Canyon slopes.