Popping out of gear

Hi All,

Advice required if I may!

I am just about to have all of the drive train rebuilt in my 200tdi. Gb/tb/both diffs.

On a few occasions now in low range difflock in 1st it has popped out of gear under strain. It goes back in fine but I have to reselect low range diff lock.

Edit - when i say popping out of gear, I think it’s more like popping out of low range and thus cutting drive.

Any idea what could be the cause of this? I assume it’s transfer box related.

thanks in advance.

Sorry I am no help but I am interested in this as my 300TDi transfer box jumps out, unless I hold it in, when I was trying to isolate a vibration. I took the front prop off and ran it around the block. I assume it is something to do with the extra pressure on the trans case only driving the rear.
Rebuild of the whole drive train is very ambitious (at least for me) if you do this I hope you take lots of pics. I will be following.
Would make a great Youtube series.