i have a 92 f250 4x4 with the BW 13-56 manual shift transfer case. I was driving without any problems most of he day today, untill I started going down a hill. I immediately started hearing a grinding noise from the transfer case. The noise went away soon as I started going up a hill and accelerating. From that point on, anytime I decelerated or let go of the throddle I heard the noise from the transfer case. I got it home and while trying to figure out what the problem is I noticed that if I shoft the transfer case into 4x4 low the truck will run in forward and reverse without any problems or noises. As soon as I put it in 4x2 high for normal operation, It will go forward when I put the transmission into D, but soon as I stop and shift the tranny to reverse nothing happens. It's as if it it goes into a neutral. At that point I can no longer go either forward or reverse untill I again put the transfer case into 4x4 low. Soon as I take it out of 4x4 low seems like the tranny/transfer case go into a neutral. I am trying to figure out if the problem is in the tranny, the transfer case, or some type of linkage adjustment between the two. the linkage does look tight and solid, nothing seems loose, and the fact that the tranny will go into forward and reverse as long as I have the transfer case in 4x4 low makes me think that the tranny is OK. I just do not know enough about the problems a transfer case can create in a drive train to say for certain that it is the problem.

Can anyone shed any light on the problem and help me determine where the problem is? Thanks in advance.

 

Sounds like the oil pump broke free inside the tcase. once the ridges in the case wear out enough the pump will spin and make the grinding noise like you stated, and usually occur at higher speeds. It's unfortunate this happens as it requires some machine work to fix, if significant damage has not been done by lack of lubrication. Best bet might be to get another tcase.

 

what type of machine work is required? a rebuilt transfer case will run about $600 from Autozone. I may look for one in a junk yard on Tuesday. What is usually involved in trying to fix this yourself? Do you havy any idea about the cost to have someone do the machine work?

BTW thanks for the response.

 

There are ridges in the case that holds the oil pump in place, these ridges wear down and have to be built up with weld, not sure on the cost.

 

I guess I will take it apart and go from there. thanks for the information.

 

I took it apart yesterday, looks like the fork is damaged at the outer ends and the plastic inserts are gone. The low/high selector gear is loose in the fork and can not engage to select either low or high 4 wheel drive. Iw nust have beem making the noise as it rubbed against the fork ends.