My transfercase motor took a dump on me today....of course it's gonna snow 14 inches tonight...so I pulled it off to examine it and test it plugged in but off the case..no luck.

But I was thinking maybe I could get it into 4x4 by putting a adjustable wrench on the shaft that the motor turns and manually turn it.The only problem is I have no idea if it's possible, will it detent to it and how much should i turn it?

Anyone with ideas, i'm all ears.

Thanks,
rob

 

My truck wouldn't shift into 4X4 and it was the relays under the hood. I was told to swap the two and see if it works.(It did) So I put in a new relay and all is good.

 

you can turn it manually there should be marks on the case under the motor good luck with thye cold snow

 

I forgot to say you still need to turn your 4x4 on the motor just turns the rod there is still a clutch pack that is magnetically controlled by the switch

 

Dan you mean turn it on via the dash switch, right?

I guess I should check those relays too...figures I have the motor off already....doh!

 

the dash switch needs to be turned on and the transfer case needs to be manually turned

 

Thanks Dan....not looking forward to digging out my truck to do this...

 

Mine doesnt have this, I have converted my esof case to manual shift, pull the lever and go. Now granted he will need to turn the switch for the hubs to lock.

 

your right I looked up the wrong tansfer case by accident either way it will still work

 

Can you tell us what you did to convert your ESOF case to manual?

 

To make a long story short, I modified the shift motor so it had an arm coming off it, added all the shift mechanism, made an adjustable shift rod with small pipe and heims, removed ESOF switch on dash, installed blank plate, volia. The stock ESOF motor needs to be left in place because it has the position sensor that tells the GEM to lock front hubs and lifht up the dash lights. So when I pull my lever, X-case locks and front hubs automatically lock, lights on dash come on.

 

I wonder what triggers the dash light for manual transfer cases?

 

this should explain it to you
Mechanical Shift-On-Stop (MSOS) System
The mechanical shift-on-stop (MSOS) system allows the operator to manually choose between 2 different 4x4 modes as well as two wheel drive (2H) and NEUTRAL. This system does not utilize a 4X4 control module. The operator can switch between 2H, N, 4H and 4L at speeds below 5 km/h (3 mph). To engage or disengage 4L, the transmission should be in NEUTRAL to alleviate residual drag torque created by the engine. This system contains manual hublocks. Prior to shifting to 4H and 4L, the front axle must be coupled to the hubs by rotating the hublocks fully clockwise to the "Lock" position.
The transfer case contains a non-synchronous clutch and Ford recommends that range shifts be carried-out at or below 5 km/h (3 mph) to prevent excessive transfer case engagement noise. When the manual shift lever is moved to 4H, the mode sleeve is moved rearward, locking the drive sprocket and chain to the rear output shaft. Moving the lever further to 4L causes the range sleeve to move rearward and engage the planetary gear set. This causes the output shaft to turn more slowly than the input shaft, resulting in increased pulling capacity at the wheels. The shift lever also operates the mode indicator switch, which triggers the instrument cluster (IC) to energize the "4x4" and/or "Low Range" indicator.

 

Yupp, thats about it. The Manual case has just a sensor that screws in the the case, where as the ESOF the encoder sensor is part of the motor, hence the reason the motor needs to still be in place when doing the conversion. I like it because of the fact my vacuum hubs still function just as they did originally. Oh and fwiw, the hole is already in the floor of the truck, just has a plastic cover over it. The manual boot screws down right in place of it so only cutting is to your carpet (or rubber mat in my case)

I grabbed a boot and lever from salvage yard, but had to buy the bellcrank that bolts to the trans from the dealer as the only one I found for a torqshift they would not sell it too me off the trans. Wholesale price was around $80 and I paid $25 for the lever and boot, $15 for a couple of 3/8'' hiems and made the rod out of scrap tubing I had, and about $7 for the blank plate for the dash to go in place of the ESOF ****, so total investment was around $130 plus a couple hours of my time. One of my best investments yet.