Ok, I have a 1999, F250 superduty, diesel, 4x4, manual transmission with 86k miles. As I was slowing to turn, I was slow to push in the clutch and felt a little bit of lash-back with a not-too-loud clank. After rounding the corner, I let out the clutch and nothing happened -- as though the truck was in neutral. There was no change in clutch pressure, no change in the feel of shifting -- for the tranny or the transfer case; and engaging the hubs and engaging 4x4 made no difference either. However, while I was shifting the transfer case, at one point, it "caught" and I was able to drive it home (less than a mile). While going home, I had to slow to go over railroad tracks and when I let out the clutch, it didn't engage until the pedal was almost all the way out and then it engaged all at once. At home, I shifted the transfer case some more to see if that made a difference and no matter what position it was in, it remained in four-low until it decided to not work at all (back to the as-if-it-were-in-neutral thing).

I have no extended warantee and the Ford guy told me he thought it was the clutch (I'm highly skeptical) and he wanted $800.00 just to look at it. I saw a couple of posts refering to the transfer cases going out, but with no replies. I'm hoping for help before I pay the big tow bill (live 60 miles from town) and take it to someone blindly, hoping they don't take advantage of me.

Brian

 

Brian, it sounded to me that what you're describing, at least in the earlier part of your post, is a clutch problem too but I'm confused about the involvement your describing with the transfer case. I'm sure that one of the guys with more experience will be able to shed more light on this for ya. Hang in there and good luck with it.

 

Before you do anything, check your clutch fluid level. If you are low, then just refill with Dot 3 Brake fluid. The T-case is wierd, though. Maybe that clank was some linkage falling apart. I know that my T-case stick got real stiff and hard to shift so I hit the linkage with some grease once in a while and everything runs like a charm.
I could be way off base with my suggestions, but they're the things you can look at first before dishing out $800. Check your fluids and linkage, anything you can examine externally is a good place to start. Good Luck!

 

I had exactly the same problem that you are describing. I lost mine going down a hill. I monkey'd around with transfer and was able to get it in 4H. I had quite a bit more to go than you did though. About 65 miles to the house. When I got there I had about 4 miles left on the warranty and had it lift towed to the dealer.... It turned out to be the forks in the transfer case. A half a day and 100 bucks and I was home again happy. Pretty freaky though. Good luck with yours..........Rob

 

Rob is correct, forks are a very common problem it that unit. Sounds like your clutch is fine, T-Case went into neutral due to the fork issue, shifting it back and forth will move it either into a gear or partway in.

 

 

Got the truck back from the tranny shop, $840.00. Indeed, it was the fork in the transfer case. The shop owner told me Ford has updated that part -- he had to order a new shaft, gear and fork because the old ones are, "unavailable." An old one couldn't be rebuilt if you wanted -- no parts available.

Ford made the fork arms thicker, the gear it moves has a bigger groove to accomodate the bigger fork arms and the gear now rides over an oil channel. (Sorry for the non-technical terms.)

Just info, when we bought the truck 12,000 miles ago, it had slack in the drive train, the kind that just about makes the drive lines ring when you make a bad shift. Well now that slack is gone.

Brian, (a much happier Brian now)