Hello all,
i have a 1356 in my 89 7.3 thats been jumping out of gear like crazy, i tore the ******* down and found my range disc had worn thru the plastic guides and started eating the aluminum range fork. I bought a new range fork for a reasonable $50, when i put it back together it seemed to have cured my problem. i drove it 7 miles and it started jumping again wtf? it wasnt "as bad" as before but its still very frustraating. does anyone have any advice or have run into this problem before? your input please
thanks

 

What do you mean jumping out of gear? If you didnt replace the guides nor the range disc its gonna keep doing that. I would replace those or get another DW1356, i have a couple if your looking for one.....are you really in Kuwait? Whats got you over there?

 

Ha ha no im just an idiot, i had just finished watching south park bigger longer and uncut so i made my profile SADDAM HUSSEIN and said i was from Kuwait lol. so your transfer cases, what condition are they in???
and its not jumping completly outta gear but when going downhill or quickly decelerating it makes a nasty clunking sound. and thats in 2wd.

 

The nasty clunking sound might be just worn out gears....how many miles are on it? Whats the truck look like? Whats the history? My transfer cases are all in great shape....the one I pulled from the 84 was hardly used....it still had that nice whine you hear from new cases that are breaking in....you could hear it doing its job and it was nice to know lol.

 

sounds like you have a bent shift fork and a worn chain. be careful, the next step is a snapped chain and cracked case.

 

How are the u-joints?? Something isn't right if the transfer case clunking in 2wd. The chain shouldn't be moving in 2wd, and the power is transmitted straight through to the rear axle. So the clunking shouldn't be coming from the transfer case.

I had a problem with mine where it jumped out of 4x4 once with quite a bang! Then I couldn't get out of my driveway... thought it was just the ice and crappy tires as the lever was still in 4x4 position. Later found out the front axle no longer turned in 4x4 hmmm... Tore it down and found a problem with the metal plate that pushes the selector forks. I don't know what exactly that part is, but its attached to the lever, and rotates when you shift the transfer case. It was a little loose on the shaft, and popped sideways so it would still rotate, but no longer contact the selector forks to shift. I think I ended up shimming it slightly with a washer so it couldn't wiggle around and haven't had any issues since. This could be part of your problem.

 

bent shift fork could be the case. it only does it in 2wd and doesnt do it in 4wd so the chain isnt spiining at all in 2wd. it could be shift fork or also the range disc, i never replaced it.. thought it look alright. thanks for the input i really appreciate it.

 

u joints are only a few months old and are still in good condition, and the transfer case gears look superb and the chain still brand new looking and ill take a look at that selector forks tecgod13 was mentioning.

thanks all for the input

 

I bet that case from the 84 is the same 1345 i have and they have a different style yoke, shift linkage and tail housing on them.

 

I maybe in need of a T case if I am unable to rebuild mine

 

there are 2 engagement pieces that wear and cause this, ford want big bucks for the male piece, i bet they are worn "tapered/ chamfered" and causing it to come out of gear, does it "buzz" when it does it?

 

Mine buzzes when it pops out of 4lo, is that the same deal? I have 2 parts transfer cases but I havent torn into it since its my DD, but if I was reasonably sure of what was worn I might tear it down.