Re: Transfer case shifting issues
Different axle ratios can sure do it! But if they are the same -
If you do have the U shaped pattern with the D-20, there's a shifter box that may be giving the trouble. See a repair manual for a drawing.
Remove t-case shifter boot, remove the 4 screws holding the shifter lever in place. Carefully remove the shifter lever itself by twisting slightly - remember which way you turned it to get it out - helps when you put it back in.
Remove the 4 screws on the bottom plate from underneath.
Now you can flush out the box with brake cleaner.
Check to make sure the sping inside isn't broken.
Carefully inspect the plate on the shifter lever - they crack and break - likely the problem of binding.
Carefully inspect the bottom end of the lever itself - they wear a groove or flat spot. You can weld up the defect, then grind it back to shape.
Test fit the lever back in again once everything's clean. Put the screws in but leave them very loose - notice how it static shifts (engine off, vehicle stopped.)
Tighten the screws a little at a time, looking for the lever to feel harder or bind. If when you get all 4 screws tight and the lever gets "stiffer", it needs a thin shim between the top cover and the housing. I found a gasket made of cardboard from an oil filter box was perfect.
Once you can tighten the top down tight and it still feels nice, remove once more. Put bottom plate back on, stuff the box with chassis grease, then put the top back on.
For some reason those shifters seem to "like" to go into gear, but "don't like" to come back out. Main culprits are cracked/broken plate, a wear groove on the shifter lever inside, or old stickey grease.
Of course a tiny dab of Locktight on the screws.
When I did mine I found a fairly large rock inside - no idea how it got in there! Must have been a PO's trail fix. Go figure.