Okay, here it goes.

Cannot seem to get my truck to lock into 4wd, every now and then it will in low but that is it. No 4x4 light in the cab, no wheels spinning and not very good in the snow.

I did notice that my OD light will flash when I put it into 4x4 Low, is this normal??? It doesn't flash otherwise...

Also when I give up and go and free up the manual hubs and jump back in, the truck wants to just dragg around the parking lot, real slow, like it is in the lowest gear ever and not going to shift up, all is in 2wd mode too???

For the final blow, I'm on my way back home after all this, the hubs are free and I here a wind for a couple seconds and then again, I cuss and notice that I had the shifter in 4H, I pop it up to 2H and it seems to be all okay.

My concerns:

Shift linkage bent up from pulling a motor a couple months back.

The FIPL and the OD light baffle me.

Lastly it not wanting to drive away freely after all this until I pop the shifter about 4-5 times from 4L to 4H and then into 2H.

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1990 F-250 4x4 w/7.3 Jasper Reman
Rebuilt IP, Rebuilt E4OD, Brake Job done, Alot of new Electric, Front End Job done.

 

Maybe you should disconnect the shifter at the transfer case, then move the transfer case thru the positions to see what you have. The shifter has a gate plate that bolts to rear of the trans, there could be some binding there seing as how it is already bent...Don

 

I want to but have not messed with tranfer cases before. Sound easy enough from what I have read. Am looking at haynes manual and trying to figure out exactly how to shift this. What do you think about the truck dragging around after working the 4wd?

 

Disconnect it right at the transfer case and unlock the hubs. Lift the rear of the truck so you can rotate the rear drive shaft. In each position you can turn the yokes to see if the case working as it should. I'm assuming this is a manual setup. For example in 4hi the front and rear shafts should be locked. 2hi the shafts will spin independant, however there will be some drag on the rear. In neutral it should feel no drag.
I think maybe your lever is moving but the transfer case lever is not. Could be the lever was in 2hi but the transfercase was in 4lo.
I have a transfercase apart right now from an 88. It is not hard to do, however a manual is a good thing. The factory manual is very good, but does not have a much for pictures. This one would not shift. The pump rotated from it's notch and jammed the linkage...Hope this helps...Don

 

had a similar problem with mine....no 4 hi, sometimes but not often 4 low (when i got stuck had to have my buddy hold the 4 low all the way back), no dash light 4x4, eventually my t case would pop into nuetral while in 2wd, ....think it has somthing to due with the shift forks...i just replaced mine had 200,000 miles on it, working great now....you can get one for around 400 rebuilt on ebay with no core so you can keep your old one and rebuild it so if you ever tear it up again....

 

Yeah, I think after I get the codes fixed that the tranny is throwing at me we'll take another look at the transfer. If it's looking like a rebuild, I saw a rebuild kit on ebay for 70 bucks. Not sure how long it will take to do the rebuild but I have all the rebuild pages from a book on it.

BTW: The codes on the tranny are saying bad temp sensor in the solonoid pack and bad vss along with high line pressure. Gonna have the solonoid pack and vss replaced in the morning.

 

Hi, I had a problem on my transfert case. Sometimes it was staying in 4 low. sometimes it would not engange. The problem was with the insert for the lever. That insert is know to get loose in the casing than the lever and fork get slack. Result: sometimes it works, sometimes it don't.
To replace the insert, you will have to take the casing apart, remove the old insert, probably drill and replace with an oversize insert.
When the mechanic took mine apart there was nothing wrong with the inside, I had 130,000 miles on it. He had a casing from a shop in Montréal Canada. If you decide to do it yourself you need special tooling to align the insert properly and to have the exact sizing.
Good luck.