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Old Dec 9, 2009 | 01:06 PM
  #1  
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cougar1985
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From: sault ste marie ontario
no 4wd

so as in a previous post i replaced a vacum actuator.2003 f150 4wd manual shift on floor for tcase.auto tranny.actuator works fine ,tcase locks front shaft to diff when put in 4 high.it will not engage 4wd no matter what,the front shaft to diff turns properly but the front wheels dont lock or nothing.anybody else have the same problem?im adding this as a question a little later ,is there anything in the front diff that could break that maybe is pretty common?like a plastic gear or pin or bolt or?anything attached to the actuator lever on the inside that would break and cause the 4wd not to engage?
 
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Old Dec 9, 2009 | 06:30 PM
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From: sault ste marie ontario
according to the ford dealer the 2003,s were notorious for the shift fork wearing out!will have to get them to fix as i dont have the time or the place to do myself .arggggh!
 
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Old Dec 12, 2009 | 12:21 AM
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Did you make sure the vacuum lines to the actuator are good?? Common problem for a vacuum line to spring a leak.
 
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Old Dec 12, 2009 | 02:48 AM
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From: sault ste marie ontario
it was the shift fork for sure ,seen. it myself.what irks me a little is the fact that ford knew they had a problem for the 2003,s have a kit for it ,but isnt covered under warrenty or anything else.any ways its all fixed and im happier now that i have 4wd back as the snow storms keep a coming (hopefully).
 
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Old Dec 12, 2009 | 08:44 AM
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From: Oshawa
how much did it cost you?
 
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Old Dec 12, 2009 | 08:45 AM
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From: Oshawa
how much did it cost you? and did you see how hard it was to do?
 
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Old Dec 12, 2009 | 09:17 PM
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From: sault ste marie ontario
Originally Posted by Gibby speed
how much did it cost you? and did you see how hard it was to do?
kit was 280 i believe from ford plus i had buggered up the axle housing tube on the passenger side being stupid!my total cost was 954 bucks!i have learned my lesson and will be a lot more careful and a lot more diligent in tracking a problem ,when it first started not engaging 4wd i should of went to ford and talked to service rep and i would of saved myself 300 bucks or more!i assumed it was one thing right away and made a big dollar bugger up by breaking the ear right off the axle tube trying to take out the vac actuator though i believe the ear was defective as i barely tapped the blasted actuator and it broke big time.yes, i had taken off the e clip!lesson learned!i bought a manual,and belong to a few sites now and will not be rushing into anything again unless im absolutly positive,lol.and if its out of my league i will be going to ford and proably save myself money . to fix the shift lever is a bit involved ,was better for me to have ford do it ,though at 98 bucks an hour it can add up fast.
 
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Old Dec 18, 2010 | 12:56 PM
  #8  
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Originally Posted by cougar1985
kit was 280 i believe from ford plus i had buggered up the axle housing tube on the passenger side being stupid!my total cost was 954 bucks!i have learned my lesson and will be a lot more careful and a lot more diligent in tracking a problem ,when it first started not engaging 4wd i should of went to ford and talked to service rep and i would of saved myself 300 bucks or more!i assumed it was one thing right away and made a big dollar bugger up by breaking the ear right off the axle tube trying to take out the vac actuator though i believe the ear was defective as i barely tapped the blasted actuator and it broke big time.yes, i had taken off the e clip!lesson learned!i bought a manual,and belong to a few sites now and will not be rushing into anything again unless im absolutly positive,lol.and if its out of my league i will be going to ford and proably save myself money . to fix the shift lever is a bit involved ,was better for me to have ford do it ,though at 98 bucks an hour it can add up fast.
Does anyone know of a good thread with pictures of taking off the vacuum actuator? I have read countless posts and all I see is breaking off ears, etc. Will the dang thing come out? I am trying to find a step by step approach. I took off the cover and thats about it. I had the wife turn the switch and the arm does not move. Only have 2wd. I replaced the transfer case motor and probably can take that back as I now learned that AINT the issue.
 
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Old Dec 18, 2010 | 05:30 PM
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Originally Posted by wrongwrench
Does anyone know of a good thread with pictures of taking off the vacuum actuator? I have read countless posts and all I see is breaking off ears, etc. Will the dang thing come out? I am trying to find a step by step approach. I took off the cover and thats about it. I had the wife turn the switch and the arm does not move. Only have 2wd. I replaced the transfer case motor and probably can take that back as I now learned that AINT the issue.
okay, replaced transfer case motor and finally got the actuator off and replaced that. 4wd still not engaging. checked vacuum lines and will check solenoids next, however, when I took off the actuator, does any know if I should be able to move the level to the fork forward or backward to engage the differential myself? I got maybe an 1" of play and that is all. When I put the new actuator on, saw that it moved back and forth but still no engaging.

Frustrated because I should have checked solenoids first and vacuum lines. If inside differential, another story because I wont tackle that in the winter with limited space.
 
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