Join Date: Mar 2010
Location: Stoney Creek, Ontario
My only solution would be to put in a New Process 205 F transfer case and end your trouble once and for all. It almost sounds like it's walking out of gear into neutral. Check the linkage adjustment first. Oil level could be low and has worn out something. I think it takes ATF.
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The Past - 1976 F-350 Crew Cab 1992 - 2006 RIP
The Past - 1995 F-150 XL Enforcer All Gear Drive 2008 - 2015
The Present - 1993 F-250 XLT Turbo Diesel Super Cab 4x4 2015 - ?
The Future - Who knows?