What if you go 3-lo, 4-lo, 4-hi?
Ed
This is what I am currently doing at the moment while rolling empty. It works beautifully and i've changed driving habit to roll in lo gears whenever empty and treat 4 hi like OD.
The truck is fine...I believe this is operator error.
It won't work right with an empty truck driving on a flat road, your ground speed is to fast and there's no load on the rear. Find a long steep hill and see if that makes a difference. If the rear works in 2nd and 3rd than it will work in 4th...it doesn't know what gear the trans is in.
With my 2-speed rear trucks I drive them all the same...start in 2-LO, 3-LO, 4-Lo and then shift the rear to 4-HI. Split shifting is only needed when the truck is really laboring to get moving.
Mike B

I fully admit that this is not out of the realm of possibility, and the thought has been in my mind. I've been running her through numerous paces over the past few weeks though, on the hills and flat roads, shifting at high and low rpms and speeds, and it seems to be constant across the board regardless of situation. But, I am rolling at a weight of only 9k lbs.
I have the new seals coming in shortly and will open up the diff for inspection and cleaning/maintenance. Ill give everything the once over to ensure all looks good. I will hold off until first load is hauled to try any more testing just to see though. I know it is just small increments of speed differences between the gears, but even just the weight of the bed makes that 3 hi - 4 hi gap pretty strong. Let me take a look this coming weekend/week and get back here to report on it.
Appreciate the info.