Hello guys, I was hoping someone would have good advice on what hopefully is a minor issue. Basically, when I shift the manual transfer case from 2H to 4H it engages easily and smoothly. The problem is when I shift into 4L; it engages very easily, but will not stay when you put the transmission into gear and put any load on it. The T-case shifter feels like it's just not quite going in as far as it should. It's not a feeling like there is a bind, more like the shifter has ran out of travel. If I keep pressure on the shifter while driving the 4-low stays in and works great, but as soon as I take my hand off it pops out and I get a gear grinding noise. Is there an adjustment on the shift linkage I don't know about? I can't believe that the transfer case is worn because it rarely sees 4H let alone 4L. Help please!

 

Definitely might be the linkage.

Gotta tell us what year truck, engine, everything. Not that it really matters with the Superduty, but the procedure to adjust the linkage might be different for different years.

 

OK, as I read my post I realized it was short of some data. The truck is a 99 F-250 Superduty w/7.3L Diesel, auto trans, 4X4 (manual hubs & transfer case), Supercab Longbed pickup with a 4" lift and larger than stock tires. She is an XLT and the only thing I wish it had was power mirrors. I'm sure I could update them but having just been laid off from Halliburton I don't think that's going to happen. So the linkage is adjustable on the transfer case? I haven't looked into the manual yet or the linkage itself.... guess I should start there!
Thanks, Jeremy

 

my guess would be linkage...

either out of adjustment or worn pivots...

no body lift right ??? body lifts can cause all kinds of shifter hassles...

 

Nope no body lift just a strait block in the rear and leafs up front. I never use the transfer case so I'd be shocked if the pivots were worn. I guess I'll see how to adjust the linkage - anybody know where to do this off the top of your head? Thanks for helping me confirm what I had thought the problem to be.

 

just a oddball idea..

but ur sure ur shifter isnt hitting the surrounding area of teh floorpan ??

maybe ur cabmounts are wearing out and the shifter is "tapping" teh floorpan..

prolly not, but worth a looksee.. either from underneath teh truck, or pull the 4WD lever into 4Lo and feel with ur fingers were it meets the floorpan and see if theres room around it still...

 

If nothing is stopping the lever from full engagement,probably the range shift fork.There are 2 plastic guides on either side of the fork that will wear and eventually fall off.When this happens,the range fork will not stay engaged on the gear, and will "pop out".

Not a hard job to do,and an inexpensive repair.You can usually buy the fork only.(with new wear pads installed).

I would eliminate all other possibilities first,as this repair requires removing and disassembling the t- case. (again not a big job)

Hope this helps.