So, I just bought my truck. It's a 1988 F-250, 7.3 IDI diesel with the ZF-5 manual transmission. The gentleman I bought it from told me that the transfer case was thoroughly serviced last year before he drove it up from California.


I went to test the transfer case shifter, and there is a LOT of play in it. I can wiggle it back and forth a good inch before it will engage 4H.


Any idea what might be causing this? Can it be fixed without pulling the transfer case?

 

I would think the case is fine. I would crawl under and see if you can see any linkages and if you can check them for wear or try to wiggle them

 

yup. loose linkage, or the bolt that holds the linkage to the t-case may just be loose.
if i remember correctly, there are nylon/teflon bushings in the arms the links go into. if they deteriorate/fall out, you will have a lot of slop in the shifters.

 

^^^What Tom said. Usually the bushings disappear and cause the slop you feel. Not too much to worry about. Even if the transfercase was shot, they're super cheap to replace.

 

Alright, so I was able to identify this as the loose connection. If I'm seeing it correctly, it looks like two bolts on the right side of the lever coming through the floor that connects it to the linkage? Could those just be loose?


Sure is easier to see things in the picture than under that truck

 

yup, it could be those two bolts are loose, or it could also be that really large one at the left of the pic.

 

it would of been easier to find out by simply grabbing a socket and ratchet and try snugging them up than to post asking.
that's the only way you'll know.we can't check them for ya. in 30 seconds you could have resolved your issue.

 

^^^^^don't listen to mr smart ***. ^^^^^^

he was once a newbie too.

 

lmao. im still a noobie.always so much to learn.

 

gotta learn somehow and turning a wrench is easier than asking when you are already under there

 

Well I did go and check them, right after I posted the picture actually. (The reason I didn't do it beforehand was because I didn't actually realize those bolts existed until I looked at the picture.) Those two small bolts were indeed loose, however after tightening them I'd estimate that the play was reduced by about 50%.


I'll crawl under again this morning and take a look, see if there's anything else that's more obviously loose now.


I'll report back later.

 

Alright, so I've identified the next loose connection. However, it appears to be some kind of pin with a retaining washer, not a bolt that I can actually tighten. Any ideas?

 

that is the teflon bushing that is worn and making the shift rod loose causing the play

 

Thanks, I figured that was it.


I can't find any information on the removal and replacement of this bushing. I tried hitting the pin out with a hammer, no luck. I don't want to beat on it so hard that I bend the linkage. No luck prying it out either. Seems like this is a relative weak point in the linkage, you'd think there would be information out there already

 

the only way to get it out is pry it out, then press it pack together with a large pair of channel locks, or vice grips.
if it works, i would just leave it be. i don't even know if you can buy those bushings anymore.