Hi, I’m Chris. Welcome and thanks for asking your question!
Is the transfer case popping out while using high or low?
When it pops out, does the dash light also change to off or a different selection?
What damage was found in the transfer case?
When it pops out, must you do anything or does it go right back in on it's own?
Does this occur during normal 4wd use or something crazy like towing or mudding or rock crawling?
Are you on dirt or grass or mud or snow when this occurs?
Does it pop out with a very harsh noise and feel from the driveline or steering wheel?
Are you using 4wd high on dry pavement or wet pavement?
Try and explain the need for 4wd high in your particular situation?
Does this seem to occur most of the time when turning?
Are all 4 tires the same brand, size, and tread depth?
Are any tires newer than the others?
Does this occur under light throttle like 10-30% or under hard acceleration or only at high speeds?
Have you ever tried low range to see if it also pops out?
Alright, thanks for all those replies.
You need to get the transfer case back out for repair. Below are 2 images showing what needs to be checked out inside.
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