Manual T-case grinding
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Elder User
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From: Boston, KY
Manual T-case grinding
I have a 1988 ZF-5 transmission with a manual transfer case (not sure the model). When I put the transfer case into 4-hi then try to let the clutch out, I get a light grinding noise and the truck goes nowhere. It's as if the transmission is in neutral. It doesn't make a difference whether or not the front hubs are locked. Any ideas what could be causing this?
Lead Driver
Joined: May 2011
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does it go anywhere in 4 low? if the linkage is fully engaging 4hi, and it goes nowhere, its time to crack it open or throw another t case on there.
I had a t case that was a wh0re to get it to fully engage into 4hi and it would grind until I got it fully engaged. there are forks in there just like a transmission, they could be worn or other components could be galled to prohibit full engagement.
I had a t case that was a wh0re to get it to fully engage into 4hi and it would grind until I got it fully engaged. there are forks in there just like a transmission, they could be worn or other components could be galled to prohibit full engagement.
Post Fiend
Joined: Oct 2003
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From: Western Central NV
If your T-Case is a Borg Warner 1356 it a good chance the fork is bad inside the T-Case. They have plastic pieces on the end of the fork that break & wear out. The fix is to replace the fork. If it goes into 4lo as asked & moves it is the fork. Had this bad luck on the freeway in Las Vegas two summers ago. I ended up just buying a used T-case for $300 & installed it. No further issue in 25,000 miles.
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Elder User
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From: Boston, KY
Great info. I'll test 4 lo and see what happens. If I'm reading things right, the problem is in the transfer case, and likely not anything to do with the rest of the front driveline - is that correct?
I could get motivated to swap the transfer case if I had to.....seems straight forward enough.
I could get motivated to swap the transfer case if I had to.....seems straight forward enough.
Logistics Pro
Joined: Mar 2011
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From: Central Wisconsin
I agree with the above statements. Fork in the TCase is junk. BW 1356 transfer cases are pretty cheap and plentiful so getting another shouldn't be a problem. BUT, make sure you get one that has the speedometer drive in the housing. I believe 1991 was the last year for this.
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Elder User
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From: Boston, KY
I'll start looking around the local salvage yards. Thanks for the heads up on the speedometer cable. I thought mine was in the tranny itself (my truck is a real Frankenstein, probably no two parts from the same year) but I'll double check before buying anything. Thanks again!
Postmaster
Joined: Nov 2011
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From: SW Florida
You could also just take it apart and replace the forks too, and do the oil pump mod while you're there.
Rebuild your own transfer case. BW1356 - FSB Forums
I don't believe in throwing things away just cause they don't work anymore, when they can be fixed easily and continue to do what I need them to do. That's just me though.
Rebuild your own transfer case. BW1356 - FSB Forums
I don't believe in throwing things away just cause they don't work anymore, when they can be fixed easily and continue to do what I need them to do. That's just me though.
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Elder User
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From: Boston, KY
That's a good policy. A few years ago I would have only considered replacement as a last resort.
Now that I have a daughter I'm more inclined to spend a little extra money if it saves me hours of frustration that could be spent having fun with my family instead. I enjoy working on the truck and spend a lot of time wrenching, but t-cases and transmissions are not my strong suit.
Now that I have a daughter I'm more inclined to spend a little extra money if it saves me hours of frustration that could be spent having fun with my family instead. I enjoy working on the truck and spend a lot of time wrenching, but t-cases and transmissions are not my strong suit.
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From: Roseville, MN
I'll start looking around the local salvage yards. Thanks for the heads up on the speedometer cable. I thought mine was in the tranny itself (my truck is a real Frankenstein, probably no two parts from the same year) but I'll double check before buying anything. Thanks again!
The variability comes in whether the truck has a mechanical speedo driving by a cable from the rear output of the t.case (or trans tailshaft if 2WD) or if it has an electronic speedo getting a signal from a VSS, which is often on the rear axle but could be on the rear output or tailshaft as well (but I think it's always on the rear axle in this vintage of Ford trucks).
* The exception to this is that you can use a 2WD trans with a divorce-mount t/case, so then you could have the speedo on the trans in a 4WD. But that's really far out of the box for '87 - '96 F-Series.
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Elder User
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From: Boston, KY
The speedo will never be off the trans in a 4WD*. 2WD trucks that have the speedo coming off the trans have it in the tailshaft housing. That's the part that's different between a 2WD trans and a 4WD trans.
The variability comes in whether the truck has a mechanical speedo driving by a cable from the rear output of the t.case (or trans tailshaft if 2WD) or if it has an electronic speedo getting a signal from a VSS, which is often on the rear axle but could be on the rear output or tailshaft as well (but I think it's always on the rear axle in this vintage of Ford trucks).
* The exception to this is that you can use a 2WD trans with a divorce-mount t/case, so then you could have the speedo on the trans in a 4WD. But that's really far out of the box for '87 - '96 F-Series.
The variability comes in whether the truck has a mechanical speedo driving by a cable from the rear output of the t.case (or trans tailshaft if 2WD) or if it has an electronic speedo getting a signal from a VSS, which is often on the rear axle but could be on the rear output or tailshaft as well (but I think it's always on the rear axle in this vintage of Ford trucks).
* The exception to this is that you can use a 2WD trans with a divorce-mount t/case, so then you could have the speedo on the trans in a 4WD. But that's really far out of the box for '87 - '96 F-Series.
Considering it is an '87 that was originally a 351w EFI, but now a carb 470, that was originally a C6 but now has a 1988 ZF, etc. etc. - nothing would surprise me. Most of the stuff on this truck was creatively pieced together.
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