2003 F250 SC Lariat. 4x4, 6spd manual transmission, Manual hubs and manual 4wd shift. The truck shifts into 4wd perfectly. When I shift back into 2wd the transfer case stays in 4wd. If I back up it will go into 2wd. Any Ideas?

 

I'm no mechanic, but maybe it's something mechanical underneath that just needs greasing or cleaning. I'd crawl underneath and look around.

 

Out of curiosity, what makes you say that it stays in 4wd after you have shifted the transfer case back to 2wd? Even with the transfer case in 2wd, if the hubs are locked, you will get a little bit of binding on the front axle when making very tight turns, although not as much as if the front driveshaft is getting power form the transfer case. You can isolate what's happening in the transfer case by unlocking the front hubs. If you shift into 4hi using the floor mounted shift lever, then you should be able to crawl under the truck (without it running or moving of course) and verify that the front driveshaft will not spin. If you shift back to 2hi on the transfer case, the front driveshaft should spin freely. If the transfer case really isn't shifting back to 2hi, the first thing to do would be to check the fluid level and color/smell in the transfer case.

 

I had an earlier model F150 that was like that. I just got used to it. Evidently the shifter was more of a "suggestion". The hubs are also a suggestion. Sometimes on my 2002 super duty they don't unlock unless you move things a little bit. You can hear it.

 

Ummm, maybe I missed something, but it doesn't sound to me like you have any problem at all.

You say you have to backup for it to shift out? That's standard procedure in a lot of 4wd vehicles....

 

i used to have Fords like that, but they were fully automatic hubs with push button 4wd. The OP has a manual 4wd shifter and just manual hubs, so he probably doesn't have to go in reverse for it to disengage

 

i know its a different vehicle but i have had several tjs and 2 xjs that you would have to back up and pull forward to unbind and unlock the tcase and front axle. my old school father in law backing up after taking his 2016 f250 out of 4wd is his normal practice today still and stands behind the fact that will unbind the system.
i would block the tires on the truck and crawl under like said with someone in the truck and have them shift into and out of 4wd while you watch the shifter and to make sure the front driveshaft is locking and unlocking.
one of my xjs after about 20 years of being beaten up one day i lost 4 lo and would have to hold the shifter in 4 lo so i crawled underneath and found a bolt that had somehow just got in the way of the shifter after a off road trip so i cut the tip of the bolt off and problem was fixed.
things shift mounts wear out frames flex and bodys flex it could be as simple as that or more serious than that

 

I own a 2006 super duty with a manual transmission. I am in and out of 4 wheel drive all the time driving down the road at highway speeds because of where I live. I rarely disengage my hubs unless I am going a couple thousand miles during the summer.


OK to the subject.


Even though the tire sizes are the same size they will turn at different rates going down the road. Either slight tire wear makes the wheels turn at different rpms. Between front and rear there is some binding. When you go from 4wd to 2wd step on the gas quickly and quickly release the gas and the transfer case should be in 2wd. If you ever shifted your manual without the clutch you have to match the engine rpm to the gear so there is no load. This is the same principle,