Truck: 97 F150 4.6 auto w/ manual shift 4x4

The speed odometer had been off bad and bouncing around for a while, and now it doesn't work at all.
The OD light flashes.
The sensor gear that 'plugs' into the transfer case was replaced and stripped again, and from what I understand all this means the speed sensor in the transfer case(what's the name?) is bad also, right?

What I'm trying to figure out is what is the procedure needed to change it?
Also, is the gear plastic or metal, and can I get it (what's the name?) from O'Reilly's or only Ford?

Thanks a lot for any help guys.

 

We have quite a few posts here on this subject. I will try later to pull one up.

There are quite a few sources to get these gears other than the dealer. esp on line. I found a source at a local trucking supply house. The gear you replaced is the driven gear. The other is call the drive gear. These have all been plastic. But other tranny models have used steel. Some have the gear machined into the output shaft. The sensor is called VSS (vehicle Speed Sensor)

Pretty simple to change. Just pulling the tail cone to access.

 

I read through most of the post, and couldn't find a description (step by step) of the process, but from what I read, it definatly sounds like it is the drive gear(which is at the end of the transfer case, right?), and the driven gear will also need to be replace again, b/c the drive gear messed it up again.
Thanks for the names.

I don't have a repair manual for this model truck, and if anyone does and is willing to type up a brief description of the process, that'd be great.

Any help would be appreciated.

 

Pulling the tailcone is pretty simple. There is one catch. There is one wre in the harness that goes thru the tailcone. So disconnecting the plug does NOT clear all the wires. That single wire goes thru a small hole to the clutch to engage for on the fly 4wd. It is just like an AC clutch. Point is that you can cut and splice that wire. Or the proper way is to extract it out of the connector.

steps:
-Pull the driveshaft. (catch oil)
-Remove the VSS. One bolt with clamps (like old distributor clamps)
-Remove the connector and the wire as noted above.
-Pull the ring of allen bolts.
-bump the tailcone loose and slide off the end (more oil)
***There is a steel ball locking the gear from sliding off. The gear is slid forward to drop the ball out, then it will slide off the shaft.
-Push the gear forward (to front of truck) Turn the shaft as it moves to see the hole in the shaft where the ball will be. You will want to catch and not lose that ball.
-Now slide the gear back and off the shaft. The gear is a snugg fit, but might slide by hand. If cocked at all it will bind on the shaft. so tap gently around it to move along. A little pressure on the opposite side of the tapping will really help. Once off it should go back on by hand.
- there is also a clip under the gear. it acts as a keyway to keep the gear turning with the shaft.
- re-assemble in opposite manner.
- there are no gaskets. Just black RTV from the factory.

(assuming it is a 4406 like my 98 has)

There is a drain plug at the bottom of the tcase. Really should change the iol while there. but not nessessary as not much oil is in the tail cone. about 2 qts of trans fluid.


Hope that helps a little.

 

The steps should really help, thanks a lot !

About the wire..... you said something about on the fly 4wd.... does that mean it's only on esof or it's on the manual cases as well?

IF It does have the wire in the manual case, would you recommend splicing the wire(with what, a butt splice?), or extract it from the connector, and how would you go about doing that?
Also, what transmission fluid does it take again....two quarts of dexron III Mercron?


You've been very helpfull, thanks a lot.

 

I do not know for certain on your manual case, but if you can enter 4wd without stopping, the answer should be yes it has one. That clutch is to get the hardware spinning before it locks in the tcase. The wire will be obvious.

You can either extract or cut. mine was already done and had a butt splice. And still does. It will require an extractor tool to pop the wire out of the harness. The tool pushes into the connector and releases the tag which keeps it from coming out.

Fliud - don't know that it matters.No clutches or seals. Just lubes the chain and gears. I believe it called for the Mercon III originally. "don't quote me" I would put the same as is in the trans.