I have a 91 f-150 w/ a 302. After the auto hubs broke I put on warn manuals. My truck didn't need the conversion kit. It goes into 4 wheel drive fine as soon as you pull back on the lever, but when you try to take it out you still have to back up a couple inches. I know this isn't normal for an all manual setup. Any suggestions?

 

actually it is alittle normal

 

On all Ford 4x4 trucks you should back the truck up about 10ft. to make sure that the hubs disengage. I've driven '78, '81, and '85 F-150s and a F-250 with auto hubs and its a go thing to do this with all of them.

 

the thing is that there are manuals in there now. You shouldn't have to back up with manual hubs. At least none that I've ever seen

 

You must realize that the driveline in a part time 4x4 system is under load when engaged. There is no differentiation between the front and rear driveshafts so they "bind" inside the transfer case. The only way to release the binding is to travel in the opposite direction that you were traveling when you shifted to 2 wheel drive. This will allow the hubs to unlock.
Mark

 

I meant to say unlock the 4 wheel drive shift collar in the transfer case not the hubs.
Mark