A year and a half ago I Shifted from 4H to 4L while on ice and i was still moving. The low gear shift fork snapped, lesson Learned. It took almost a year before I mustered up the time and money to fix it. This past spring I ordered the parts a new low gear shift fork and a new oil pump. I installed these parts and was very happy to see that it was easy to repair the T.C.
I tested the job on a gravel lot everything was fine. Last week I tried to put it into 4L the gears engaged but the dash light indicator wouldnt stay lit unless I kept a light pressure on the shift lever. The transmission was in nuetral and I was stoped in my driveway. After rolling backwards few feet it stayed in and I was able to put the truck up on the ramps. I changed the clutch out and reassembled everything went for a test drive top speed, 25mph. not cool. checked the linkage it was hooked up correctly. I then took out the T.C. opened it up and the low gear shift fork and the oil pump are messed up again.
Has anyone had trouble rebuilding a T.C. or is there something that has a critical alingment that the Ford sevice manual doesnt mention

 

there's a groove in the inside of the tcase that the oilpump sits in. if this groove is damaged the pump will spin freely,

check this forum thread, there's a post by f250freak with a pick of one mod to be done to the oil pump to prevent stripping of the channnel in the tcase for the oil pump.


hope this will help

 

Well, if it is a groove problem then there is a good fix to it. If you look in my gallery under the t-case you can see what did to cure it.