Transfer case prob.
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Postmaster
Joined: Nov 2008
Posts: 2,851
Likes: 3
From: Buckley, WA
Transfer case prob.
after i did my zf5 swap i aslo put on the t-case that came with it...ever since then the following happens:
-4hi wont engage if tranny is put in reverse (4lo is fine)
-in 1st and 2nd gear in 4hi will grind and whine when the clutch gets pressed in and wont stop until i throw the transmission into neutral
-and i got a double cardon front shaft that is louder then my previous shaft...almost like the ujoint yokes are hitting...because it has a steady rhythm to it as my speed increases
any thoughts? i just checked the fluid today and the u joints are tight
thanks
-4hi wont engage if tranny is put in reverse (4lo is fine)
-in 1st and 2nd gear in 4hi will grind and whine when the clutch gets pressed in and wont stop until i throw the transmission into neutral
-and i got a double cardon front shaft that is louder then my previous shaft...almost like the ujoint yokes are hitting...because it has a steady rhythm to it as my speed increases
any thoughts? i just checked the fluid today and the u joints are tight
thanks
Elder User
Joined: Dec 2002
Posts: 559
Likes: 0
From: South Carolina
Several thoughts...
Is this a transmission issue or a t-case issue?
Are the t-case shifter pattern plate and link the ones for the ZF, or for the prior transmission? There are several combinations possible, some may not work as well as others. You should have the transfer case lever that has to rock sideways to get past 4hi into Neutral, then into 4lo. The pattern plate and link usually have the application embossed on them somewhere.
Is there play at the manual lever on the transfer case itself, or is it nice and tight?
This transfer case is not hard to work on, but you will need 2 snap ring pliers, the kind for "eyed" snap rings, and "blind" snap rings, and a (T47?) torx bit to unbolt the case.
It might be easier if we start with symptoms for transmission first gear only.
Is this a transmission issue or a t-case issue?
Are the t-case shifter pattern plate and link the ones for the ZF, or for the prior transmission? There are several combinations possible, some may not work as well as others. You should have the transfer case lever that has to rock sideways to get past 4hi into Neutral, then into 4lo. The pattern plate and link usually have the application embossed on them somewhere.
Is there play at the manual lever on the transfer case itself, or is it nice and tight?
This transfer case is not hard to work on, but you will need 2 snap ring pliers, the kind for "eyed" snap rings, and "blind" snap rings, and a (T47?) torx bit to unbolt the case.
It might be easier if we start with symptoms for transmission first gear only.
Thread Starter
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Postmaster
Joined: Nov 2008
Posts: 2,851
Likes: 3
From: Buckley, WA
Several thoughts...
Is this a transmission issue or a t-case issue?
tcase issue? transmission works perfect in 2H
Are the t-case shifter pattern plate and link the ones for the ZF, or for the prior transmission? There are several combinations possible, some may not work as well as others. You should have the transfer case lever that has to rock sideways to get past 4hi into Neutral, then into 4lo. The pattern plate and link usually have the application embossed on them somewhere.
i took all of the linkages from the donor truck, only thing that i didnt take was the shifter itself
Is there play at the manual lever on the transfer case itself, or is it nice and tight?
no, its pretty loose. so yea id call it play
This transfer case is not hard to work on, but you will need 2 snap ring pliers, the kind for "eyed" snap rings, and "blind" snap rings, and a (T47?) torx bit to unbolt the case.
takin one apart before but just curious to see what i should look for when im inside it
It might be easier if we start with symptoms for transmission first gear only.
Is this a transmission issue or a t-case issue?
tcase issue? transmission works perfect in 2H
Are the t-case shifter pattern plate and link the ones for the ZF, or for the prior transmission? There are several combinations possible, some may not work as well as others. You should have the transfer case lever that has to rock sideways to get past 4hi into Neutral, then into 4lo. The pattern plate and link usually have the application embossed on them somewhere.
i took all of the linkages from the donor truck, only thing that i didnt take was the shifter itself
Is there play at the manual lever on the transfer case itself, or is it nice and tight?
no, its pretty loose. so yea id call it play
This transfer case is not hard to work on, but you will need 2 snap ring pliers, the kind for "eyed" snap rings, and "blind" snap rings, and a (T47?) torx bit to unbolt the case.
takin one apart before but just curious to see what i should look for when im inside it
It might be easier if we start with symptoms for transmission first gear only.
thanks
Elder User
Joined: Dec 2002
Posts: 559
Likes: 0
From: South Carolina
Play at the manual lever on the t-case can let the mode/range plate inside wiggle out of place. you'll have to open it up to see, but I'll bet the plate inside that links the mode and range forks is not staying put. If it does not rotate "true" around the manual shaft, it can let the mode and range forks be partly engaged. You can grab it with your fingers and wiggle it side to side to check for play. If the pins for the forks do not stay in the zig-zag holes, the case may have wear at the manual shaft.
Thread Starter
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Postmaster
Joined: Nov 2008
Posts: 2,851
Likes: 3
From: Buckley, WA
oh ok the lever on the tcase itself...missed that i meant the shift **** had a ton of play. tomorrow in the light i will check that out...if its bad ill open it up. partly engaged i think hit the nail on it, at least thats how it feels/sounds
Thread Starter
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Postmaster
Joined: Nov 2008
Posts: 2,851
Likes: 3
From: Buckley, WA
sorry forgot to update this... but your not going to believe this but when i did my zf5 swap i drained the tcase and FORGOT to fill it!!! all the noises and grinds went away.....yikes that was bad
Elder User
Joined: Nov 2009
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Senior User
Joined: Aug 2010
Posts: 189
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From: Port Washington, Wi
3 years ago my buddy did that on his 91 f250. Drove it until it would start to lock up coming to a stop. Got some atf, filled it up and it was fine. Been fine ever since 
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