2000 f-150 4x4 4.2 auto with manual T-case
It was rebuilt by ford in Feb of 2007, Have not used it since. Went to use it today and it will not shift. Crawled under and linkage is intact,moves when someone moves left to right but not down into 4 hi or 4 low--no 4x4 indicator lit. I cant remember if when in 2 wheel if shift lever moved right to left--the diagram shows 2hi down to 4 hi "then" Left into 4 low. It is like it is jammed or pinned into place any and all help would be desperatley need

Semper Fi Chris

 

On my 94 F250 4x4 the transfer case can be a bit stubborn. I have heard this of other manual transfer cases too.

Seems like the key to making the transfer case easier to shift is to make sure the engine is at idle, the truck is not moving and you are in park or neutral. My guess is that the input and output shafts etc want to be either all moving at the same speed or not moving at all. 4L is very picky on my truck.

Seems like if you stop and then try to quickly shift the transfer case it will sometimes not budge or clang when it does shift. Also even if you do put things in neutral it might still not like it. If you put it back into gear and move a few feet it seems to fix that. I am guessing the movement lines things up at a spot that is easier to shift into.

When I shift on the fly say during nasty road conditions, I make sure I am going at 35mph or less and not accelerating or decelerating a lot, and then I shift it into 4H. Once in a great while I might need to shift into neutral to get it in gear while I am coasting.

I know very little on the technical aspects of the transfer case, but this has been my experience with my F250 since I bought it used with 36K miles and now I have something like 93K.

Good Luck,

Jim Henderson

 

Thanks for the reply. I have had no less 10 f150 4x4 trucks with manual transfer case shiftshift, this sucker won,t budge

 

Same thing happend to my '98 F150. Had to replace the 4w drive shift linkage. Works great now.