Hey guys,

I have a 99 F250SD 4x4 (5.4l). I did a clutch in it about 1 year ago. Last night going home, I was driving on the freeway and I hit the gas to pass a car when the rpm went up but the truck didn't move, just like if I have the clutch in. I pulled over, it made a lood noise, comming from the tranny, and I was free wheeling, just like if the clutch was pushed in. I stopped, and when I was slowing down the front differential, or whells, was making some kind of grinding noise, not constant but at one spot at every rotation of the wheels. I tryed to put it in 4x4 or in gear, couldn't go anywhere. I can shift in all teh gear without problem, without pressing the clutch pedal. the shifter feels right, and it is acting just like I was shifting into gear with the clutch pedal push, except I am not pushing the pedal!! the pedal feels fine too. It's fine to put it in any gear including reverse except for the 5th where it grinds a little but it goes in. I town the car home and the front differential noise was still there and when away after a little bit. It's very weird. If the clutch was stuck disengaged, like if the fork got stuck crooked and depressed the clutch, the pedal would feel weird, but it doesn't. Could it be the input shaft on the tranny that broke or the teeth got ground on the shaft or the clutch plate?? but in that case, I would not get any problem shfting it in any gear at all, but here the 5th grinds!! I don't know. It is very weird. Any opinions would help. I guess I'll take it apart tomorrow and see but I fear the worse!! thanks

Michel

 

Might be your t-case. Might have defaulted to neutral, which would cause it not to be able to move in 4WD or 2WD. I assume electronic or vacuum t-case? Some are manual in which case my theroy is busted. Since everything else feels fine...

Disclaimer: I'm not a mechanic, but I have a basic knowledge of how it all works. I am known to look at the simple side of things and that's how I came up with T-case.

Let us know!

 

I'll also second the T-case. As I recall there was some type of problem with some of the earlier cases that would cause them to go into neutral even though there is no neutral with shift on the fly.

 

I don't think he would be able to move throughout the gears with the tranny spinning, he might though. The t-case does sound like the culprit.

 

I did a quick check and it seems the problem was for the manual transfer case. It seems the shift forks can wear causing it to go into neutral. It is recommended that the case be replaced rather than repaired. Part # F81Z-7A195-KC for 6sp and F81Z-7A195-HC for 5sp and auto.

 

I was thinking about that too, but how can I shift into gears without the clutch engaged without grinding?? If the transfer case is dead, the tranny still spins, no? and even if there is no load it would still grind!? In this case I don't know if I need to remove the tranny. Something that worries me is the noise I heard in the front differential!!? by the way my hubs were locked but I was in 2WD when that happened.........so confused.......

 

Sounds like the input shaft broke. Or the clutch plate blew up.

 

that is what I first thought but it would be making noise when idling, no? it would still be rubbing together. And I have never heard of a broken input shaft, they seem pretty strong especially when that happened, I wasn't trying to climb a tree or tow a house!! But with my luck it could be that anyway anyway, I'll have to take it appart next WE, it was too cold last WE.
thanks guys,

Doowop

 

SO, i finally looked at it!! it was loud from the transfer case. Took it out and it was making a noise when I turned it by hand. It seems to be that. I started the engine and ran the tranny by itself, and everything seems ok. I pull the trasnfer case from under the truck and turned it by hand but it doesn't make any moremoise at all and everything seems to be working fine!!! When I shift it in 4x4 or 2x4 it seems fine. weird. There was a little bit of metal in the oil, but nothing much. I think there is definitelly something wrong with the TC but it coudl just be something minor. Anybody has ever opened one of those?? That would suck to pay $1000 for a rebuilt one if this one only needs a $150 part. Any advice? I was gonna stop by a transmission shop to see when they say.

 

HuH? What are you saying? You took it out and put it back! I don't understand where are you at with it now?

 

nono! I took it out, as soon as it was out I rotated it by hand and it was making a noise just like before, but once I pulled it out from underneath the truck and rotated it again, the noise was gone. When I shifted it into 4x2 or 4x4 by hand (on the ground), it seems to be working fine now. But there is no load or anything. It doesn't make the noise anymore. It seems like some part was out of place and when I moved the TC, it got back in place, somehow! Very weird!! ANybody ever opened one of those??

 

So its still out. Put it in 2wd hi and put a pipe wrench on both ends taking care not to mar the surfaces and turn in the opposite way to see if you can slip it. If it snapped inside..you will be able to tell maybe if you can get enough torque on it. If it made a noise once there should be a problem with it but by hand you just can't do it.

 

ok guys,

finally took everything apart. It was one of the fork inside. Totally chewed up!! the part in the center of it was just going trough it. Ford was only selling that part in a kit that was $500!! I looked on the web and found Drive train of las vegas. They sell the part by itself for $56!!! I also got a oil pump since I was at it for an extra $30. Put everything back together and it works great!!!
My only concerne it why it happened? I fit is because of something else, it might happend again, but maybe it is just wear because the little teflon things came loose! Anyway, there is nothing in a transfer case. It is cake to take it apart and work on it. I am glad I am a mechanic. If I took is somewhere it would have been $2000 and I ended up spending $100!!! I love it!! Thanks for your input guys!!

 

I am unclear, it was your t-case shifter and not your tranny? In any case, it is great you fixed it yourself! Thanks for letting us know the final result.

 

It was one of the fork that is inside the TC.