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I'm a new poster on this sight, but have learned a lot just from following various threads here. But I have a problem I haven't seen before. I'm looking to buy a '95 F-150 5.0L 4X4. Truck is in very good shape and drives nice (slight pull to right w/ both lockouts on). The real issue is shifting out of 2H is nearly impossible. I can pull slightly, but not enough to get to the 4H hole and no farther. Even at that small amount, it does engage the front wheels. From the looks of this truck, previous owner seldom if ever used 4WD or left the roadway for that matter. Beside the fact this truck has been sitting for a few months. Is it possible the linkage is just froze up from inactivity? Can this be freed up with a heavy dose of P.B. Blaster? Or is this more likely one I should steer clear of unless I'm willing to do more learning about the underside of Ford trucks?
I'm not sure they still used the NP208 then, but I had one that didn't shift right at all. The gears weren't where they were supposed to be and I couldn't get it all the way back into 4hi. Turned out the shifter fork was worn almost off and had to be replaced - along with a few other parts. Cost ~$300 for a guy that knows what he's doing to fix it, after I pulled it and took it too him.
I would suspect transfer case problems, problems with unmolested factory linkages should be non-existent (or at least rare and only under extreme circumstances).
That's a late model truck. It may have the later transfer case like mine does. To shift mine you have to pull the lever over to your leg, and then pull it back. And they do like to rust and stick. It has a gate down underneath the floorboard on the shifter mechanism. It has a arm that pivots on a large bolt, and this arm fits in this gate. When you pull the lever toward your leg, you are lifting the tip of the arm out of the gate so you can pull it back. This large bolt likes to rust and freeze up. A little wd40 will loosen it up.
WI uses road salt in the winter. It's quite likely the linkage is rusted if 4WD was rarely used in almost 20 years. If PB Blaster or WD40 don't do the trick, user a 50/50 mix of acetone and ATF, that's the most effective rust penetrant. Don't forget the safety glasses, you don't want acetone in your eyes.
You can also use the inability to get it in to 4WD as a negotiating tool. Either they get it fixed or knock off $500 or so because you'll need to "get it fixed".
If the linkage is rusted you will need to replace it, however If it's not rusted, you can crawl under neath it, and take a pair of pliers or screwdriver and bend the metal over to make the linkage tight again, I had to do that on my old f150 it was getting stuck or going into a gear but not actually changing over. That may be able to solve your issue