Hey all, I have a '93 f150 with a 302, automatic. I have the manual 4wd shifter that goes 2WD, 4WD Hi, N, 4WD Lo. Low range 4wd has always been difficult to engage with the shift lever, however this past snow storm I went to use the 4wd (just in high range) and a loud snap happened and my shift lever went all loosey goosey like it was no longer attached to anything down in the transfer case. With some careful jostling, it would still go between 2wd and 4hi. After a few days I was cruising down the road in 2wd and it pops out of gear, and the 4wd lever no longer engages any gears. Even when my truck was in Park, it would still roll. I talked to a friend and he mentioned the transfer case manual shift linkage? Apparently an aluminum part that costs hundreds of dollars... anybody have any insight to this? Can I get the linkage out by just laying under the truck or is this like major transfer case/transmission surgery? Can I reweld it together or do I really need a brand new one? Thanks for any info.

Ed

 

Mine did something similar, it turned out to be the shift fork inside the transfer case was worn out. I assume it has the BW 1356 case in it. If so there are two forks inside, one controls mode (2 or 4wd) the other controls range (4hi or 4lo). I would bet its the mode fork worn and not letting the slider engage properly.

It is a fairly easy fix, you will need a good set of snap ring pliers. Google exploded diagrams of the case then crack it open to see exactly what is wrong in there. If the shift fork is bad, you can order one of them for @ $30. I would suggest maybe replacing the slider too. I've had mine out a few times and ordered parts from a place named Cobra Transmission. I'd suggest checking out the oil pump in it too, they are notorious for breaking.

I'd almost put money on the mode fork being worn out. Not hard to fix and less than $100.

 

most of the time it is a broken shift linkage outside the t-case. the hint to me it is outside is the fact it has been binding foe a while and snapped when forced.

if you get under the truck with a wrench you should be able to shift the t-case back into 2 wheel manually and run it until you get the parts to fix it.

 

Thanks for your help, I got under the truck and right in my face was the snapped aluminum shift linkage that goes into the transfer case, so I put the truck in N and muscled it back into 2WD. Drove it the half hour home and ran just fine, so I have til next winter now to get it replaced! Thanks again fellas.

 

I guess what would concern me is when you said it just 'popped out of gear'. Could that happen again?

 

I'm sure it could.. that's why I was nervous to drive it home because it was in 2wd when it originally popped out, but it could have been only partially in gear because the linkage was already snapped at this point and I just pushed until the 4wd light went off. Could have still been in 4wd, not sure..

 

It'll only come out of gear again if the mode or range shift fork is damaged... if it was just loose linkage not allowing a complete shift then it should be fine now since he made sure it engaged this time. The detent spring in the case will keep everything in place even without the lever connected.

 

Here is a link on how to prevent the issue after you repair yours:
https://www.ford-trucks.com/forums/1...er-repair.html