Stock 1975 GMC 3/4 ton pickup with np205 put shifter into Drive you hear a clunk and bell ding telling you truck is in gear and all is normal..... randomly under power or when stopping t case shifter will pop into neutral and you cannot get it to go into place (even with copious grinding) unless steering column shifter is put into neutral, pull shifter all the way rearward to engage again, then put into Drive... rinse lather and repeat multiple times per trip or have to hold 205 shifter rearward for entire trip which it still tries to pop out
Agreed on all T-cases having to be shifted from Neutral. I was having a similar issue with a 203 popping out of gear though. Turns out the shifter linkage wasn't letting it engage all the way so I twin sticked it to get rid of that linkage all together. 205 has a simpler linkage but might be worth checking.
Sounds to me like the op has abused the t-case by shifting it while in gear. Most likely the gears are chipped, broken or worn out by now, also by trying to force it in gear while not in neutral the op could have damaged the shifter forks.
the np205 has a slider that contacts small teeth on the gear, generally known as a "dog".
when trying to push the lever into high or low range, the following can occur, or can occur during normal wear and tear.
if you wear the slider, surely you realize that the dogs on the gear will also wear, but the jumping out of gear may be from the dogs being worn in a different manner, by acceleration/deceleration over a long period of time.
the dogs will be angled or shaped in a manner that will not allow the slider to maintain contact under load.
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