Electric Transfer Case Shift
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Senior User
Joined: Feb 2002
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From: Mill Creek, WA
Electric Transfer Case Shift
I've been looking at some new-to-me trucks and Bronco's (92-96 range) and many of them seem to have the electric shift transfer case. I had originally said to myself that I wanted to keep options as manual as possible for reliability reasons, but with so many out there, it's got me thinking...
Just how reliable are these? Or, how problematic? And in case the motor does die or I have another problem (what other problems are common) -- how bad are they to work on?
Thanks,
Adam
Just how reliable are these? Or, how problematic? And in case the motor does die or I have another problem (what other problems are common) -- how bad are they to work on?
Thanks,
Adam
Post Fiend
Joined: Mar 2002
Posts: 19,402
Likes: 38
From: Bonita Springs FL
You're right to want the manual shift. Less to go wrong. The electronic transfer case motor is the failure point. It needs regular maintenance to work when you want it to. And even then...
For best results, stick with a manual transfer case and manual hubs. You can find them if you look around. That's how my Bronco came from the factory, and it's a loaded 5.8L Eddie Bauer.
For best results, stick with a manual transfer case and manual hubs. You can find them if you look around. That's how my Bronco came from the factory, and it's a loaded 5.8L Eddie Bauer.
Postmaster
Joined: Jul 2006
Posts: 3,978
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From: Central PA
I don't have a problem with them (power case) till around 125000 thats when the trucks I have worked on seem to start acting up. But I have a 93 with 159000 mile and it still works . My 94 has 139000 and is fine. but I have a rebuilt x-fer case with manual goodies waiting to go in. Good luck on search. I drove 500 miles 1 way to get mine and hauled it home. (120000 Bad motor but rustfree original paint)
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Senior User
Joined: Feb 2002
Posts: 224
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From: Mill Creek, WA
Thanks for the replies.
So when they go, it seems to be the motor that goes. How bad is that to replace? R&R transfer case or do it in the truck? How much work are we talking?
Adam
So when they go, it seems to be the motor that goes. How bad is that to replace? R&R transfer case or do it in the truck? How much work are we talking?
Adam
Fleet Mechanic
Joined: Mar 2005
Posts: 1,603
Likes: 1
From: St Louis
The only major problem I have had with my electric transfer case is the range fork wore out letting the truck jump out of gear. You can pull the electric motor from the back of the transfer case with very little issue. Just depends on the magnetic spin up clutch as that wire has to be pulled from the harness or cut and spliced, as well as the 4wd sensor. The problem to notice on the manuals is that the shift shaft does wear and become oblong with use. It requires a very careful hand to drill out the hole and place a new insert into it. A common problem with both versions of the transfer case is the plantary gear set. It is what produces the range of High and Low. A thrust washer is all that separates the plantary set from the main input shaft. If this gets badly worn, it will cause a truck to shift to neutral at a really bad time. Other than leaks from old seals, the transfer case is reliable but not as, to borrow a term, bullet-proof as the the old new process 205. Only way to get a np 205 in the 80's to 97 trucks is basically a swap in from an older truck.
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