On my 1996 f150 5.0 4X4 with push button 4 wheel drive. i believe from what lookin ive done on here i have the Borg Warner 1356 Electric Shift.
Now my problem , when i accelerate from a stop if i really baby it i wont get the chug. But when i just start off normally , say around 5 to 10 mph ill get one chug. Everytime i accelerate this happens. When im driving . its fine nothin out of the ordinary. ONLY at stops .I had my truck on a lift and the u joints are in good condition. but when i spun my drive shaft it seemed like there was play in the transfer case. I cant figure out where this 5 to 10 mph clunk could be coming from. Its not a little clunk either, anyone riding in my truck can clearly notice it. Thanks guys

 

I would check the condition of both engine mounts and the transmission mount. I would also check that the slip joint in the front driveshaft is greased and slides freely.

 

the mounts seem to do ok, and the u joints are healthy and i greased them . How do i check the slip joint?

 

Unbolt it from one end and see if it slides easily.

 

it slides freely, and i drove the truck in 4wd in the be 4low and it does it too. i never tried . (the clunk feels like i have something in the bed and when i get going it smashes on the back of the tailgate.)

 

loose tailpipe?

 

Wonder if your shift motor limit switch adjustment is slightly off, not engaging 4 wheel fully resulting in a skip bang under increased load.

 

MY dual exhaust is brand new, and for good measure i checked any way. Everything is in order

 

I never heard of that or knew of that part. How would i check into this?

 

does it matter if it does this in 2wd, so does that tell us its not the shift motor limit switch?

 

Shift motor might need cleaned/lubed, rather then adjustment. Unless you can clearly see it had moved recently. Might be just dirty/corroded and or badly worn and weak because of it, unable to fully rotate shifter shaft.

Fairly simple to do so, be sure and mark its currant position before removal, you'd want to reinstall in that same position for testing once cleaned/lubed.

I wouldn't continue driving it, allowing it to chug bang or skip, until the problem is located and corrected.

 

Ya your right i prob shouldn drive my truck. Ide love to remove this part and try to see if it will fix my problem but im still not sure of the part you guys are speaking of, Is it the transfer case electric motor that operates the 4wd?

 

Is it the transfer case electric motor that operates the 4wd?
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Yea it mounted on the back of the transfer case, fairly easy to remove/reinstall. If its like the little trucks though there is part of the harness to it that doesn't unplug at that point.

Makes it a tad tougher to deal with, if you can at all help it do not cut the wires, work on it under the truck. If you find it necessary to do so be sure to solder and then heat shrink seal those connections to make em water tight again. IIRC its battery power/ground that doesn't simply unplug.

I haven't had the honor of working on one of the f150's, I had a little ranger and two of the little broncos with the push button TC shift.

I much prefer the manual lever, while the electric shift is ok and for the most part seamed trustworthy enough it is electric and down under the truck in all the crap.
Often a few taps with a hammer while attempting to shift, vibrating the shift motor some will get ya in a gear or the gear you want, gets it home where a appropriate repair can be done. All I ever had to do was clean and fresh lube to get em working right again.
The adjustment aspect will become apparent once you get a look at how it's mounted/works.
Shaft shift positions are marked on the back of the tc and can be clearly seen with it removed.

In a pinch if the truck wiring or its control module is the problem for example, you can unplug it, use a length of wire from the battery down to it to jog the shift motors position to get the gear desired. Don't suggest you try that until you have a clear understanding how it works, what does what.

 

ya my 4 wheel works fine, i tested it in 4 and low. but im gonna get the truck on a lift tuesday mornin and check out the motor. thanks for the help