Need Help Pinpointing Transfer Case Issue
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1st Gear
Joined: Oct 2025
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Need Help Pinpointing Transfer Case Issue
(1990 Bronco E4od with bw1356 manual shift transfer case)
A couple weeks ago I was coasting down a hill in my bronco when there was a sudden bang followed by grinding. At first I thought it was the transmission, but I’ve narrowed it down to the transfer case.
I’m now trying to pinpoint the problem from whether it’s the shift linkage mechanism playing up or the internals. I’ve flushed the transfer case fluid and there was nothing worrying in there.
So everything works normal in 4lo but in 4hi and 2wd I’ve got no reverse and drive is hesitant. As shown in the videos, putting the car into drive while in 2wd it will either heavily clunk into drive or I push the transfer case lever while it’s already in 2wd and it bumps it in. If I try that in reverse, it just grinds. Any help would be greatly appreciated.
A couple weeks ago I was coasting down a hill in my bronco when there was a sudden bang followed by grinding. At first I thought it was the transmission, but I’ve narrowed it down to the transfer case.
I’m now trying to pinpoint the problem from whether it’s the shift linkage mechanism playing up or the internals. I’ve flushed the transfer case fluid and there was nothing worrying in there.
So everything works normal in 4lo but in 4hi and 2wd I’ve got no reverse and drive is hesitant. As shown in the videos, putting the car into drive while in 2wd it will either heavily clunk into drive or I push the transfer case lever while it’s already in 2wd and it bumps it in. If I try that in reverse, it just grinds. Any help would be greatly appreciated.
Logistics Pro
Joined: Jun 2009
Posts: 4,823
Likes: 83
From: Cedar Rapids, IA
You may want to try removing the front driveshaft that runs from the transfer case to the front axle to see if that maybe is binding. Or I suppose you could also try locking your front hubs and putting the transfer case in 2wd to see if it has a nasty binding or vibration since that too should cause the axle to rotate.
-Rod
-Rod
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