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I just bought a 96 F350 7.3 diesel w/150k. The transfercase will not shift into 4 wheel, most of my experience is with 1/2 ton chevys and wranglers. Any help or ideas would be greatly appreciated.
Shifter is froze up on the large pivot shaft/bolt, spray the heck out of it with penetrate over the next few days until you can unscrew the bolt. Then clean and lube it right, if you try force it to free it up you will snap the shifters lower casting. Getting hard to come by and rather pricey when you find a good one.
Two 13/15" bolts hold it to the side of the trans, you can remove the bolts easier working from in the cab through the floor if you remove the screws and slide the shifters boot up out of the way.
Work on freeing the pivot once you have it off the truck, takes minutes to remove and just plain easier.
You should have the push down for "N" and "4Lo" style shifter, be sure and free that up while you have it off/apart.
If needed clip zip ties top and bottom to remove little rubber boots, lube and free up nicely and then re install boots with new zip ties.
Thanks for the heads up. I'll start hosing it with penetrating oil in the morning and the advice is greatly appreciated as the cold weather and snow will be coming sooner rather than later here in Ohio.