Back to driving the 91 daily , need to fix a few things on it

1) the transfer case won't engage 4high . No problem getting 4 low. In gear or reverse it won't engage. Might be a linkage issue, but could there be anything else internal?

2) the manual zf-5 shifter has devolved about 2" of sloppy travel, even while in gear I can move the shifter around. I understand there is a bushing in there that needs replacing? What is it called or anyone have the part number?

3) the ignition will only get power if I move the tilt wheel on the column down and up once. I have the glow plugs on a switch and the starter on a switch...is that something that will eventually break and stop working all together? Because it never used to be this bad lol never had to move the tilt wheel to get power.

Any insight on these issues? Thanks guys

 

On my 90 the 4hi is finicky. It has to be "just right" otherwise it isn't engaged and I'm in neutral. I'm thinking slop in the linkage.

For the column i wonder if your wiring harness is getting pinched or worn and power is getting interrupted. When you move the column maybe the wires touch again and power flows?

Just some hypothetical on my part.

 

Pull the connection from the transfer case to the lever off and move it by hand. If you leave the transmission in neutral, you should be able to feel when it engages. If you can shift it through all the positions, it's just a linkage issue.
The ignition switch is on the top of the steering column, down under the dash. It's held on with 2 nuts, and has 1/2" of adjustment. Loosen the nuts and adjust until it works properly.
If it still doesn't work properly, remove the switch and actuate it manually.

 

If you still have power troubles after adjusting the switch position on top of the column you should check the upper switch actuator that is located inside the upper part of the column below the steering wheel. When this part breaks the switch will not work properly if at all.

I believe the part number is 3F527.