I'm posting this for a friend but he is too lazy and/or stupid to figure it out for himself. He has an 89 F250 7.3L IDI 5 speed 4x4 (standard cab, 8ft bed). While driving, usually down shifting, the tranfser case will pop out of gear into Neutral. Then he has to stop, put the T-case back in gear and then he can keep going.

My question is what would be causing this and if its something where it has to be completely torn apart, is it just worth replacing the whole t-case? I've never torn a t-case (or tranny) apart and I don't know how well it would go over.

 

You can get used TCases for $100, sometimes cheaper off of craigslist. They're usually not worth rebuilding as they are plentiful and cheap.

It sounds like the linkage might be binding, or the forks are worn out.

 

Yeah I'd say the shift forks are worn or damaged. My electric shift t-case would randomly go into neutral sometimes. The oil pump retainer broke loose, spun around and trashed the forks.

Used t-cases are cheap, my local yard charges the same price as a transmission for one ($130) and if it's bad you can return it and pull another.

As far as rebuilding one, it's easy. Not much in there really. Chain, cogs, planetary gear set, oil pump, and all the usual pieces like bearings and seals.

I didn't like the lazy-man's electric shift one bit (what genius thought of that abomination?) so I went to my yard and got a worn-out manual shift model. Rebuilt it with parts from Southwest Gear (and I probably used a couple small pieces from my old electric shift t-case too) and bolted it in. Works great and I have the satisfaction of a job well done, a real lever to shift with, plus the knowledge of how it works, and the comfort of knowing it was done right and will last a long time.

 

wasnt there an all gear one for manuals and one with a chain for an auto. i know it was like that on a slightly older pickups

 

I believe all the BW 1356's were the same with the exception of the electronic ones and a special one for HD trucks.

 

I know some of these trucks had the BW 1356 under them.That's what I've got. I don't know exactly the timeframes, but the NP208 and/or NP205 might have been an option? And the BW1345 maybe?

I'm sure somebody will chime in and eliminate some of those, but that's what I've got coming to mind. Maybe I'm thinking back too far though..

I also don't know what dictated which transfercase was used.

 

OK, thanks for the help. I'm not sure which one it is just yet, I havent crawled under the truck to look at the tag. My 87 f150 4 speed has the BW 1356. I have no idea if they had the same tcase in a 3/4 ton or not. I'm just going to tell him to get another one and hopefully its not junk. Theres a good chance its bent because it used to be a plow truck, I hate plow trucks, everything gets screwed up on them.

 

Some of the info I found on the 'net lead me to believe 1987 is the first year for the B-W 1356 on the F-series trucks. There should be a tag on the one already on the truck to confirm.

 

All gear t-cases have NOT been used since 79
80 and up are aluminum housings with chains